High performance, reinforced insulated precast concrete and tilt-up concrete structures and methods of making same

ABSTRACT

The invention comprises a product. The product comprises a foam insulating panel, the panel having a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, the at least one recessed channel being sized and shaped to provide a mold for a structural reinforcing member. The product also comprises a concrete panel formed on the first primary surface and filling the at least one recessed channel so as to provide a structural reinforcing member for the concrete panel. The product further comprises an elongate anchor member in the foam insulating panel and extending from the first primary surface of the foam insulating panel into the concrete panel. A method of making a composite reinforced insulated concrete structure is also disclosed.

FIELD OF THE INVENTION

The present invention generally relates to the forming of concretestructures. More particularly, this invention relates to precastconcrete structures, especially precast and tilt-up concrete panels. Thepresent invention also relates to insulated precast and tilt-up concretepanels, especially architectural structural loadbearing precast andtilt-up concrete panels. The present invention also relates to areinforced insulated concrete panel or structure that uses less concreteand reinforcing steel than a conventional structure or panel. Thepresent invention also relates to methods of making insulated precastconcrete structures and insulated precast tilt-up concrete structures,especially concrete panels. The present inventions relates to aninsulated precast roof panel system. The present inventions also relatedto highway noise barrier systems that can absorb and reflect sound. Thepresent invention further relates to a highly energy efficient buildingsystem that reduces energy consumption.

BACKGROUND OF THE INVENTION

In the United States, approximately 40% of energy consumption is used toheat and cool buildings. In buildings, the majority of energy loss takesplace through the building envelope. The building envelope consists ofdoors/windows, exterior wall systems and roofing systems. In additionbuildings should not only be energy efficient but also should be able towithstand natural disasters, such as floods, hurricanes, tornadoes,earthquakes, and the like. Therefore, building envelopes needs to beboth resilient and highly energy efficient.

Framed walls use metal or wood studs to build a frame that can be eitherloadbearing or infill. Multistory buildings can be made fromcast-in-place concrete with the exterior perimeter walls being in-filledframe construction. Exterior sheathing is attached to the outside of theframe. On the inside, drywall is typically used for the inside finishsurface. This framing system creates a cavity between the exteriorsheathing and the drywall. This cavity is then filled with battinsulation to improve energy efficiency. It is assumed that the R-valueof the batt insulation determines the energy efficiency of the wallsystem. However, there are several drawback of this system. Framingmembers create thermal bridging. Batt insulation may not completely fillthe cavity wall and over time it can sag, leaving no insulation in someplaces. Moisture condensation inside the cavity wall is common whichdampens and compresses the batt insulation. When this occurs, the dampbatt insulation loses most, if not all, insulating properties. HVACsystems create pressure differentials between the interior and theexterior of the building. These pressure differences cause air to movethrough the exterior wall system. Simply stated, cavity wall framedsystems have poor energy efficiency, among many other problems. Inaddition, framing construction has a very poor record sustaining stormand flood damage. More and more jurisdictions require use of resilienthome construction systems. In fact FEMA has an entirely newcertification for resilient homes and means to prevent damage arisingfrom natural disasters.

Exterior walls can also be made of concrete, either pre-cast orcast-in-place. Concrete is a composite material comprising amineral-based hydraulic binder which acts to adhere mineral particulatestogether in a solid mass; those particulates may consist of coarseaggregate (rock or gravel), and/or fine aggregate (natural sand orcrushed fines). While concrete provides a long lifespan and increasedprotection from damage, concrete is as cold or as hot as the ambienttemperature. Concrete has high thermal mass, which makes it ratherexpensive to heat or cool in extreme temperatures. In an attempt toalleviate this problem, the inside of a concrete building may beinsulated. However, such insulation does little to improve energyefficiency as it is generally on the wrong side of the wall; i.e., theinterior wall surface. Concrete walls have the advantage that they arebarrier systems; i.e., no air can flow through from inside to theoutside, but still have poor energy efficiency. While concrete-typebuilding construction does very well in storms and floods, it does notdo as well in seismic areas due to its massive weight and minimalflexibility.

Precast or structural concrete wall panels are known in the art. The useof precast concrete wall panels has gained in popularity because theycan be manufactured at a remote location, transported to a job site andattached into place, usually be welding steel embeds to a building'ssteel structural frame. Precast structural panels can also be formedboth onsite and offsite and used to support a loadbearing structure ofone to four stories tall. Precast concrete panels can be reinforcedusing standard deformed steel reinforcement (rebar) or stressed cables,such as pre-stressed or post tension cables. Generally these concretepanels are of a uniform thickness, the thickness of which is determinedby the anticipated stresses to be placed upon the concrete panels orstructure.

Prior art precast concrete wall panels also have a large thermal masswhen exposed to ambient temperatures. They retain the heat in the summeror the cold in the winter very well. Therefore, buildings built withprecast concrete panels generally have relatively poor energyefficiency. Such buildings usually require a relatively large amount ofenergy to keep them warm in the winter and cool in the summer. Sincemost precast concrete panels are not insulated, they must be insulatedon the inside through the use of interior framing systems. This methodhowever does not create a highly energy efficient building envelope.And, since batt insulation of significant thickness is required theinterior frame system takes valuable floor space and creates a cavitywall.

More recently, new methods of insulating precast concrete panels havebeen employed. There are a number of insulated concrete panel systemscurrently employed. All of them are a “sandwich” type panel. Such panelsrequire placing a layer of foam between two relatively thick layers ofconcrete. Some panels are non-composite while others are compositetypes. Regardless of which type is used, all concrete insulated sandwichpanels are made of uniform concrete thickness on each respective side ofthe foam panel.

One method involves placing a layer of insulation between a structuralconcrete layer and an architectural or non-structural concrete layerduring the casting of the panel and then erecting this entirenon-composite construction as an exterior panel. While this methodimproves the insulating properties of a wall and therefore the energyefficiency of a building, it has several drawbacks. Instead of havingone layer of concrete, the “sandwich” creates two; one that isstructural with the larger thermal mass that faces the inside of thebuilding and is insulated from the elements. The second layer ofconcrete is slightly thinner and placed on the exterior of the building;i.e., on the side of the panel opposite the insulated structural layer.Although the second layer is thinner than the first layer, it usuallyincludes steel reinforcing bars (“rebar”). Rebar has to have a minimumembedment of 1½ inches from the exterior face of concrete and is usuallyplaced in the center of the concrete. Therefore, the thinnest exteriorconcrete is still approximately 3 to 4 inches thick of uniform thicknessof each respective layer. The second layer is therefore still relativelythick and heavy. The weight of the second layer added to the weight ofthe first layer makes the entire panel relatively heavy. The AmericanConcrete Institute and industry practice requires that no shear forcesbe exerted by the first and second layers of the “sandwich” on theinsulating layer. Therefore, a bond breaking layer is applied to theinsulating layer so that neither the first nor the second layer willadhere thereto. Since there is no bond between the two layers ofconcrete and the foam, the ties used to connect the two concrete layershave to be engineered to resist the shear pressure from the weight ofthe second layer of concrete. Generally this is a costly system.

Other methods of sandwich panel construction involve a layer of foambetween two wythes (layers) of concrete in a composite type assembly.The inner and outer wythes can be the same thickness or the inner wythecan be thicker while the outer wythe can be thinner. Some use compositeplastic ties to hold the two wythes together while others use carbonfiber mesh. Some sandwich panels use pre-stressed cables to achieve therequired strength while others use internal trusses. However thesepanels are heavier and therefore more expensive to manufacture. Sincethe exterior wythes are made from conventional concrete, they are stillconsiderably thick due to minimum steel embedment code requirements. Thethinner the concrete wythes, the more brittle they become which requiresuse of pre-stressed cable reinforcement or expensive carbon fiberreinforcements. To place the steel embedments, attachments andreinforcement, the thinnest practical concrete thickness is limited toapproximately 2 to 3 inches of uniform thickness of each respectivewythe.

Concrete structures and panels are used to provide the load bearingcapacity and to carry the loads or stresses of the structure. Verticalpanels or walls are used to carry the roof loads and the load ofintermediate floors. Horizontal slabs are used to carry the live loads,such as furniture and occupants of a structure. To achieve theseproperties the concrete has to be reinforced with steel. Concretestructures and panels have to be designed to safely withstand varioustype of loads or stresses, such a dead loads, live loads, wind loads,and seismic loads within an appropriate amount of deflection. Howeversome of these loads are not equally distributed along a structure orpanel. For instance, on each side of an opening there are greaterstresses than in the middle of a long span wall. Additionally, buildingcorners have greater stresses than the middle of a building side wall.Certain elevated slab or roof elements are connected to the walls atcertain locations thereby distributing a larger load in that specificarea than another. At these locations additional steel is used toreinforce the concrete. However the overall thickness of a concretepanel or slab is generally determined by the maximum concrete thicknessrequired in the areas of maximum stress. Therefore, a concrete panel'sor slab's thickness is the same in areas of maximum stress as in theareas of minimal stress and consequently is of a uniform thickness.Also, since steel reinforcement has to be continuous, generally thetype, size and amount of steel from the areas of maximum stress arecarried over into the areas of minimal stress. This creates anunnecessary amount of concrete and steel used in the areas of minimalstress that is not needed. While this is a known factor, the limitationof construction practices makes it impractical and expensive to formconcrete panels with various concrete thicknesses and varying steelreinforcement to accommodate the various stresses within a concretepanel or slab. In addition, the aesthetic appearance of a concrete panelwith various structural reinforcing elements cast within may not bedesirable.

Almost all precast, tilt-up and concrete slabs are made of concrete ofuniform thickness throughout. The insulated concrete sandwiched panelsmentioned above also have concrete slabs of uniform thicknessthroughout.

Precast concrete panels are also used to construct highway noisebarriers. Concrete noise barriers are used to deflect noise away fromthe protected areas. Concrete panels cannot absorb noise; they onlydeflect it. It is know that foam panels can absorb sound. Some stateshave used foam panels for sound barriers. However the structurallimitations of the foam panels make them prone to other shortcomings.Some states, such as Georgia, have discontinued the use of foam panels.Also, while concrete noise barriers may be longer lasting, they areheavy and have very limited architectural features.

Generally roof structures are built using a system of steel beams, steelroof joists and corrugated metal roof deck. To provide insulation to theroof, insulation board is attached to the metal deck using fastenersgenerally spaced 24 to 36 inches on center. A roof membrane is thenattached to the foam board using an adhesive. In certain cases, the roofmembrane is attached using fasteners. While such roof systems are verypopular, they are highly susceptible to storm or wind damage.

To create a roof system that can withstand hurricane force winds,concrete is typically poured on top of the corrugated metal deck. Then,insulation is attached to the top of the concrete. In some caseslightweight concrete is poured on top of the metal deck. Sincelightweight concrete is a better insulator than regular concrete, someprojects will attach a roof membrane directly to the top of the concretewithout any insulation. While this provides greater wind resistance, itis not a very energy efficient roof system.

The biggest drawback of any roofing system that uses poured concrete ona metal roof deck is that the metal deck acts like a pan and it collectsmoisture. Since concrete needs to be moisture cured in order to achieveits maximum strength, additional water may be sprayed onto the concrete.Furthermore, lightweight concrete has significant amounts of air pocketsand types of aggregate that retain water. Due to weather andconstruction schedules, roof membranes are sometimes applied while thereis still significant moisture in the concrete. This moisture retained bythe concrete is therefore trapped between the metal deck on the bottomof the concrete and the roof membrane on the top. Due to weather cycles,this trapped moisture has nowhere to go but up thereby causing failureof the roof membrane with resulting potential severe damage to theinterior of the building.

Due to the specific design limitations, precast insulated sandwichconcrete panels are seldom if ever used for a roof deck.

Therefore, it would be desirable to provide a system for relativelyeasily and efficiently insulating precast concrete panels or otherstructures to achieve the highest energy efficiency possible. It wouldalso be desirable to provide a precast concrete panel system thatprovides a concrete form for casting structural reinforcing elementswithin the precast cementitious-based or cementitious panel or slab. Itwould also be desirable to provide a concrete panel that uses reducedamounts of concrete and reinforcing steel compared to conventionalconcrete panels or slabs. It would also be desirable to provide acomposite precast insulated concrete panel that is lighter and strongerthan prior art panels so that it can have improved performance in anytype of natural disaster. It would also be desirable to provide aninsulated precast concrete roof deck that does not trap moisture in theroof system. It would be desirable that the insulated precast concreteroof panels have greater energy efficiency and wind load resistance.

It would also be desirable to have a highway noise barrier system madeof composite precast insulated concrete panels that are both soundabsorbing as well as sound reflective. It would be desirable that suchhighway noise barrier system panels have the option to integrallyinclude a wide range of architectural finishes. It would also bedesirable to provide an integrated architectural finished compositeprecast insulated concrete panel that can incorporate all necessaryreinforcing elements required by localized stresses within the panel orslab. It would also be desirable that such panels efficiently integratea wide variety and types of cladding, finish textures, colors, andpatterns, such as concrete, plaster, stucco, stone, brick, tile and thelike.

SUMMARY OF THE INVENTION

The present invention satisfies the foregoing needs by providing animproved concrete precast or tilt-up or slab construction system.

In one disclosed embodiment, the present invention comprises a product.The product comprises a foam insulating panel, the panel having a firstprimary surface and an opposite second primary surface, wherein the foaminsulating panel defines at least one recessed channel in the firstprimary surface, the at least one recessed channel being sized andshaped to provide a mold for a structural reinforcing member. Theproduct also comprises a concrete panel formed on the first primarysurface and filling the at least one recessed channel so as to provide astructural reinforcing member for the concrete panel.

In another disclosed embodiment, the present invention comprises aproduct. The product comprises a concrete panel having a first primarysurface and an opposite second primary surface and having at least twoparallel reinforcing columns, beams or rib on the first primary surfacethat at least partially define a cavity therebetween. The product alsocomprises a layer of foam insulating material having a first primarysurface and an opposite second primary surface, wherein the secondprimary surface of the foam insulating material contacts the at leasttwo parallel reinforcing columns, beams or rib and fills the cavitytherebetween. The product further comprises a layer of reinforcingmaterial disposed on the first primary surface of the layer of foaminsulating material.

In another disclosed embodiment, the present invention comprises amethod of making a concrete structure. The method comprises preparing ahorizontal form of a desired shape for a precast concrete structure, theform having a bottom. The method also comprises preparing at least aportion of the bottom of the form from a foam insulating material,wherein the foam insulating material defines at least one recessedchannel sized and shaped so as to form at least one concrete structuralreinforcing member in the precast concrete structure. The method furthercomprises placing plastic concrete on the first insulating material sothat the plastic concrete fills the at least one recessed channel andforms a layer on the first insulating material, whereby the secondportion of the elongate anchor member is embedded in the plasticconcrete.

In another disclosed embodiment, the present invention comprises amethod of making a concrete structure. The method comprises preparing ahorizontal form of a desired shape for a precast concrete structure, theform having a bottom. The method also comprises preparing at least aportion of the bottom of the form from a foam insulating material havinga first primary surface and a second opposite primary surface, thesecond primary surface of the foam insulating material defining at leastone recessed channel sized and shaped so as to form at least oneconcrete structural reinforcing member in the precast concretestructure, a layer of reinforcing material disposed on the first primarysurface. The method further comprises placing plastic concrete on thesecond primary surface of the foam insulating material so that theplastic concrete fills the at least one recessed channel and forms alayer on the foam insulating material.

In another disclosed embodiment, the present invention comprises aroofing system. The roofing system comprises a precast concrete panelhaving a first primary surface. The roofing system also comprises alayer of foam insulating material having a first primary surface and anopposite second primary surface, the second primary surface of the layerof foam insulating material attached to the first primary surface of theconcrete panel and a layer of reinforcing material disposed on the firstprimary surface of the layer of foam insulating material. The inventionfurther comprises an elongate anchor member penetrating the layer offoam such that a portion of the anchor member is embedded in theconcrete panel and an enlarged portion of the anchor member captures aportion of the layer of reinforcing material between the enlargedportion and the layer of foam insulating material. The invention alsocomprises a roofing membrane disposed on and attached to the layer ofreinforcing material.

In another disclosed embodiment, the present invention comprises aroofing system. The roofing system comprises a precast concrete panelhaving a first primary surface. The roofing system also comprises alayer of foam insulating material having a first primary surface and anopposite second primary surface, the second primary surface of the layerof foam insulating material attached to the first primary surface of theconcrete panel and a layer of reinforcing material disposed on the firstprimary surface of the layer of foam insulating material. The inventionfurther comprises an elongate anchor member penetrating the layer offoam such that a portion of the anchor member is embedded in theconcrete panel and an enlarged portion of the anchor member captures aportion of the layer of reinforcing material between the enlargedportion and the layer of foam insulating material. The invention alsocomprises a layer of cementitious material on the layer of reinforcingmaterial. The invention also comprises a roofing membrane disposed onand attached to the layer of cementitious material.

In another disclosed embodiment, the present invention comprises aroofing system. The roofing system comprises a precast concrete panelhaving a first primary surface. The roofing system also comprises alayer of foam insulating material having a first primary surface and anopposite second primary surface, the second primary surface of the layerof foam insulating material attached to the first primary surface of theconcrete panel and a layer of reinforcing material disposed on the firstprimary surface of the layer of foam insulating material. The roofingsystem further comprises an elongate anchor member penetrating the layerof foam such that a portion of the anchor member is embedded in theconcrete panel and an enlarged portion of the anchor member captures aportion of the layer of foam material between the enlarged portion andthe concrete panel. The roofing system also comprises a roofing membranedisposed on and attached to the layer of foam insulating material.

In another disclosed embodiment, the present invention comprises abuilding structure. The building structure comprises a precast concretepanel having a first primary surface and a layer of foam insulatingmaterial having a first primary surface and an opposite second primarysurface, the second primary surface of the layer of foam insulatingmaterial attached to the first primary surface of the concrete panel.The building structure also comprises a layer of reinforcing materialdisposed on the first primary surface of the layer of foam insulatingmaterial. The building structure further comprises an elongate anchormember penetrating the layer of foam such that a portion of the anchormember is embedded in the concrete panel and an enlarged portion of theanchor member captures a portion of the layer of reinforcing materialbetween the enlarged portion and the layer of foam insulating material.The building structure also comprises a layer of cementitious materialdisposed on the layer of reinforcing material. The building structurefurther comprises a pair of vertical columns horizontally spaced fromeach other, whereby the precast concrete panel is attached to the pairof vertical columns such that the precast concrete panel is disposedvertically.

Accordingly, it is an object of the present invention to provide animproved insulated concrete tilt-up construction system.

Another object of the present invention is to provide an improvedinsulated precast concrete panel or slab system.

Another object of the present invention is to provide an improvedinsulated reinforced concrete panel system.

Another object of the present invention is to provide an improvedinsulated concrete panel system that incorporates various structuralreinforcing elements of different thickness in the areas of maximumstress and uses less concrete and reinforcing steel in the areas ofminimal stress.

A further object of this present invention is to provide a method ofconstructing a highly energy efficient building envelope.

Another object of the present invention is to provide an improved methodfor making a concrete structure.

A further object of the present invention is to provide an improved formfor an insulated precast or concrete tilt-up panel that can form variousstructural reinforcing elements of different thickness in the areas ofmaximum stress and uses less concrete and reinforcing steel in the areasof minimal stress.

Another object of the present invention is to provide an improvedinsulated precast concrete panel.

Another object of the present invention is to provide a precast concretepanel whereby the expansion and contraction due to the temperaturechanges is significantly reduced, or eliminated, thereby reducing theinternal stress in the curing concrete thereby reducing the amount ofreinforcement necessary within the panel.

A further object of the present invention is to provide a tilt-upconcrete panel whereby the expansion and contraction due to thetemperature changes is significantly reduced or eliminated, therebyreducing the internal stress in the curing concrete thereby increasingthe useful life span of the structure.

Another object of the present invention is to provide a precast concretepanel with a system for attaching a wide variety of wall claddingsthereto.

Yet another object of the present invention is to provide a precast tiltup concrete systems that can be cast on any level, solid surface.

A further object of this present invention is to eliminate the bondformed between the concrete panels and the casting surface, therebyreducing the amount of force required to break such a bond and therebyreducing the size of the lifting equipment required to lift the panelsby making a lighter panel by using less concrete and reinforced steel.

Still another object of the present invention is to provide a tilt-upinsulated concrete panel with a system for applying decorative finishesto the insulated surface thereof.

Another object of the present invention is to provide a tilt-up concreteforming system that allows the tilt-up concrete panel to be erected morequickly than prior art systems.

Another object of the present invention is to provide an improvedprecast concrete construction system.

Another object of the present inventions is to provide an improvedinsulated precast system that can be cast on pre-stressed cable tablesof any length and then cut to size in the desired lengths.

Another object of the present invention is to provide more sustainableand environmentally friendly concrete construction system that uses lessraw materials and energy.

A further object of the present invention is to provide an improvedroofing system.

Another object of the present invention is to provide an improved soundabatement structure.

These and other objects, features and advantages of the presentinvention will become apparent after a review of the following detaileddescription of the disclosed embodiments and the appended drawing andclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially cutaway perspective view of a disclosed embodimentof an insulated concrete form for a precast or tilt-up compositeinsulated concrete panel in accordance with the present invention. Someof the rebar has been eliminated from FIG. 1 for clarity.

FIG. 2 is a cross-sectional view taken along the line 2-2 of theinsulated concrete form shown in FIG. 1 shown without the layer ofinsulating material.

FIG. 3 is a cross-sectional view taken along the line 3-3 of theinsulated concrete form shown in FIG. 1 shown without the layer ofinsulating material.

FIG. 4 is a partial detailed view of the insulated concrete form shownin FIG. 3.

FIG. 5 is a partial detailed view of the insulated concrete form shownin FIG. 4.

FIG. 6 is a cross-sectional view taken along the line 6-6 of theinsulated concrete form shown in FIG. 1 showing a disclosed embodimentof a layer of insulating material on top of the insulated concrete form.

FIG. 7 is a cross-sectional view taken along the line 7-7 of theinsulated concrete form shown in FIG. 1 showing a disclosed embodimentof a layer of insulating material on top of the insulated concrete form.

FIG. 8 is a cross-sectional view of a concrete form shown for a concretepanel in accordance with the present invention shown with an exteriorcoating on the foam insulating panel and optional side form members.

FIG. 9 is a cross-sectional view of a concrete form shown for a concretepanel in accordance with the present invention shown with an exteriorcoating on the foam insulating panel and optional side form members.

FIG. 10 is a partial detailed view of the composite insulated concretepanel shown in FIG. 9.

FIG. 11 is a partially cut away perspective view of a disclosedembodiment of a composite reinforced insulated concrete panel inaccordance with the present invention.

FIG. 12 is a partially cut away perspective view of an alternatedisclosed embodiment of a composite reinforced insulated concrete panelin accordance with the present invention.

FIG. 13 is a cross-sectional view taken along the line 13-13 of theinsulated concrete form shown in FIG. 12.

FIG. 14 is a cross-sectional view taken along the line 14-14 of theinsulated concrete form shown in FIG. 12.

FIG. 15 is a partially cutaway perspective view of a disclosedembodiment of a reinforced insulated concrete panel in accordance withthe present invention shown being used as a part of a building structureor as a sound abatement panel.

FIG. 16 is a cross-sectional view taken along the line 16-16 of thereinforced insulated concrete panel shown in FIG. 15.

FIG. 17 is a cross-sectional view taken along the line 17-17 of thereinforced insulated concrete panel shown in FIG. 15.

FIG. 18 is a cross-sectional view taken along the line 18-18 of thereinforced insulated concrete panel shown in FIG. 15.

FIG. 19 is a partial detail cross-sectional view of the reinforcedinsulated concrete panel shown in FIG. 17.

FIG. 20 is a partially cutaway perspective view of a disclosedembodiment of a reinforced insulated concrete panel in accordance withthe present invention shown being used as a roof.

FIG. 21 is a partially cutaway perspective view of an alternatedisclosed embodiment of a reinforced insulated concrete panel inaccordance with the present invention shown being used as a roof.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

U.S. patent application Ser. No. 13/247,256 filed Sep. 28, 2011 and Ser.No. 13/626,087 filed Sep. 25, 2012 are both incorporated herein byreference in their entirety.

Referring now to the drawing in which like numbers indicate likeelements throughout the several views, there is shown in FIG. 1 adisclosed embodiment of a precast or tilt-up concrete form 10 inaccordance with the present invention. The insulated concrete form 10rests horizontally on a previously formed, and at least partially cured,concrete slab 12, which forms a floor of a proposed building (notshown). Alternately, the concrete form 10 can be used on any solid,level, casting surface, such as a casting table for making precastconcrete panels or also vertically in a precast battery mold. In certaincases, the concrete form 10 can be used to form an elevated slab in themanner disclosed in applicant's co-pending patent application Ser. No.13/247,133 filed Sep. 28, 2011 (the disclosure of which is incorporatedherein by reference in its entirety). The concrete slab 12 has ahorizontal flat upper surface 13. The insulated concrete form 10includes a rectangular foam insulating panel 14. The foam insulatingpanel 14 can be made from a single piece of foam or from multiple piecesof foam joined together, as described in U.S. patent application Ser.No. 13/247,256 filed Sep. 28, 2011 and Ser. No. 13/626,087 filed Sep.25, 2012 (the disclosures of which are incorporated herein by referencein their entirety). In this disclosed embodiment, the foam insulatingpanel 14 is 20 feet tall and 40 feet wide. This is a size of a concretepanel that may be used for building a two-story high warehouse building,such as a home building supply store or a warehouse grocerystore/general merchandise store, single family home residence or anymultistory building construction. Of course, any size concrete panel orslab can be constructed in accordance with the present invention byusing foam insulating panels of different sizes or a larger or smallernumber of such panels. When pre-stressed cables are used for internalreinforcement, the concrete form can be 200 to 600 feet long by 12 to 15wide. In such case multiple panels can be cast at once as a continuouspanel and then cut to the desired length.

The foam insulating panel 14 can be made from any insulating materialthat is sufficiently rigid to withstand the pressures of the concreteplaced in the form and from workers walking on the foam insulatingpanel. The foam insulating panel 14 preferably is made from a polymericfoam material, such as molded expanded polystyrene or extruded expandedpolystyrene. Other polymeric foams can also be used, such aspolyisocyanurate or polyurethane. The foam insulating panels should alsohave a density sufficient to make them substantially rigid, such asapproximately 1 to approximately 3 pounds per cubic foot, preferablyapproximately 1.5 pounds per cubic foot. Expanded polystyrene isavailable under the trademark Neopor® and is available from GeorgiaFoam, Gainesville, Ga., USA. Extruded polystyrene is available from DowChemicals of Midland, Mich., USA. The foam insulating panel 14 can bemade by molding to the desired size and shape, by cutting blocks orsheets of pre-formed extruded expanded polystyrene foam into a desiredsize and shape or by extruding the desired shape and then cutting to thedesired length. Any number of foam insulating panels can be joinedtogether to provide a form bottom of a dimension equal to the desiredheight of the concrete panel being formed. If the foam insulating panel14 is made from polystyrene or from a material other than polystyrene,the foam insulating panel should have minimum insulating propertiesequivalent to approximately 0.5 to approximately 8 inches of expandedpolystyrene foam; more preferably at least 0.5 inches of expandedpolystyrene foam; most preferably at least 1 inch of expandedpolystyrene foam; especially at least 2 inches of expanded polystyrenefoam; more especially at least 3 inches of expanded polystyrene foam;most especially, at least 4 inches of expanded polystyrene foam.Preferably, the foam insulating panel 14 has insulating propertiesequivalent about 0.5 inches of expanded polystyrene foam; about 1 inchof expanded polystyrene foam; about 2 inches of expanded polystyrenefoam; about 3 inches of expanded polystyrene foam; or about 4 inches ofexpanded polystyrene foam.

Optionally, applied to the lower (i.e., bottom) surface of the foaminsulating panel 14 is a layer of reinforcing material 16 (FIG. 16), asdisclosed in applicant's co-pending patent application Ser. No.12/753,220 filed Apr. 2, 2010; Ser. No. 13/247,133 filed Sep. 28, 2011;Ser. No. 13/247,256 filed Sep. 28, 2011; and Ser. No. 13/626,087 filedSep. 25, 2012 (all of which are incorporated herein by reference intheir entirety). The layer of reinforcing material 16 can be made fromcontinuous materials, such as sheets or films, or discontinuousmaterials, such as fabrics, webs or meshes. The layer of reinforcingmaterial 16 can be made from materials such as polymers, for examplepolyethylene or polypropylene, from fibers, such as fiberglass, basaltfibers, aramid fibers or from composite materials, such as carbon fibersin polymeric materials, or from metal sheets, such as steel or aluminumsheets or corrugated sheets, and foils, such as metal foils, especiallyaluminum foil. The layer of reinforcing material 16 can be adhered tothe outer surfaces (i.e., the bottom surface when the panel is in ahorizontal position or the exterior surface when the panel is in avertical position) of the foam insulating panel 14 by a conventionaladhesive. However, it is preferred that the layer of reinforcingmaterial 16 be laminated to the lower surface of the foam insulatingpanel 14 using a polymeric material that also forms a weather ormoisture barrier on the exterior surface of the foam insulating panel.The weather barrier can be applied to the layer of reinforcing material16 on the surface of the foam insulating panel 14 by any suitablemethod, such as by spraying, brushing or rolling. The moisture barriercan be applied as the laminating agent for the layer of reinforcingmaterial 16 or it can be applied in addition to an adhesive used toadhere the layer of reinforcing material to the outer surface of thefoam insulating panel 14. Suitable polymeric materials for use as themoisture barrier are any water-proof polymeric material that iscompatible with both the material from which the layer of reinforcingmaterial 16 and the foam insulating panel 14 are made; especially,liquid applied weather membrane materials. Useful liquid applied weathermembrane materials include, but are not limited to, WeatherSeal® byParex of Anaheim, Calif. (a 100% acrylic elastomeric waterproof membraneand air barrier which can be applied by rolling, brushing, or spraying)or Senershield® by BASF (a one-component fluid-applied vapor impermeableair/water-resistive barrier that is both waterproof and resilient)available at most building supply stores. For relatively simpleapplication, where cost is an issue or where simple exterior finishsystems are desired, the layer of reinforcing material 16 can beomitted.

A preferred elastomeric weather membrane is a combination ofWeatherSeal® and 0.1% to approximately 50% by weight ceramic fibers,preferably 0.1% to 40% by weight, more preferably 0.1% to 30% by weight,most preferably 0.1% to 20% by weight, especially 0.1% to 15% by weight,more especially 0.1% to 10% by weight, most especially 0.1% to 5% byweight. Ceramic fibers are fibers made from materials including, but notlimited to, silica, silicon carbide, alumina, aluminum silicate,aluminum oxide, zirconia, and calcium silicate. Wollastonite is anexample of a ceramic fiber. Wollastonite is a calcium inosilicatemineral (CaSiO₃) that may contain small amounts of iron, magnesium, andmanganese substituted for calcium. Wollastonite is available from NYCOMinerals of NY, USA. Bulk ceramic fibers are available from Unifrax ILLC, Niagara Falls, N.Y., USA. Ceramic fibers are known to block heattransmission and especially radiant heat. When placed on the exteriorsurface of a wall, ceramic fibers improve the energy efficiency of thebuilding envelope.

Optionally, Wollastonite can be used in the elastomeric weather membraneto both increase resistance to heat transmission and act as a fireretardant. Therefore, the elastomeric weather membrane can obtain fireresistance properties. A fire resistant membrane over the exterior faceof the foam insulating panel can increase the fire rating of the wallassembly by delaying the melting of the foam.

The foam insulating panel 14 includes at least one, and preferably aplurality of recessed transverse channels, such as the channels 18-26,that extend the full width of the foam insulating panel. On thetransverse peripheral edges of the foam insulating panel 14 aretransverse half-channels 28, 30 that extend the full width of the foaminsulating panel. On the longitudinal peripheral edges of the foaminsulating panel 14 are longitudinal half-channels 32, 34 that extendthe full length of the foam insulating panel. The half channels 28-34are so designated because they define a bottom and one side of thechannel; the opposite side of the channel is defined by the form sidemembers discussed below. Intermediate the longitudinal half-channels32-34 is a longitudinal channel 36 that extend the full length of thefoam insulating panel 14. Intermediate the channels 18-26 and thehalf-channels 28-30 and between the channel 36 and half-channels 32-34are elevated islands 38-48 and 50-52 (only two of six are shown).

The channels 18-26, 36 and half-channels 28-34 can be of any suitablecross-sectional shape, such as circular, oval, V-shaped, dovetail andthe like, but in this disclosed embodiment are rectangular incross-section. The channels 18-26 and half channels 28, 30 are parallelto and equally spaced from each other. Similarly, the channel 36 andhalf-channels 32, 34 are parallel to and equally spaced from each other.Of course, depending on design criteria, such as panel size, anticipatedwind loads and the like, other number, spacing and/or arrangement of thechannels and half-channels can be used. For example, if a window, a dooror other opening is to be included in the precast panel, it may benecessary to frame such members with corresponding channels in the foaminsulating panel 14, which therefore creates a concrete beam, column orstructural reinforcing rib which reinforces the panel around and openingfor the door or window. The foam insulating panel 14 can be made bycasting in the desired shape and size or by cutting the channels 18-26,36 and half-channels 28-34 into a sheet of foam of the desireddimensions, such as by cutting with a knife, a saw, a router, or a hotknife. Alternatively, the islands 28-48 can be cut to the desireddimension and then adhesively attached to a foam panel of uniformthickness, thereby defining the channels 18-26, 36 and half-channels28-34 therebetween.

The foam insulating panel 14 includes a plurality of panel anchormembers, such as the panel anchor member 54. Each panel anchor member 54is preferably formed from a polymeric material, such as polyethylene,polypropylene, nylon, glass filled thermoplastics, thermosettingplastics or the like. For particularly large or heavy structures, thepanel anchor member 54 is preferably formed from glass filled nylon. Thepanel anchor member 54 can be formed by any suitable process, such as byinjection molding or pultrusion. The panel anchor member 54 can also bemade from metal, such as by casting, stamping and other suitableprocesses. The design of the panel anchor member 54 is disclosed in moredetail in applicant's co-pending patent application Ser. No. 13/626,087filed Sep. 25, 2012 (the disclosure of which is incorporated herein byreference in its entirety). Alternative designs for the panel anchormember are disclosed in applicant's co-pending patent application Ser.No. 13/247,133 filed Sep. 28, 2011; Ser. No. 13/247,256 filed Sep. 28,2011 and Ser. No. 13/626,087 filed Sep. 25, 2012 and in applicant'sco-pending patent application entitled “Hybrid Insulated Concrete Formand Method of Making and Using Same” filed contemporaneously herewith(the disclosures of which are all incorporated herein by reference intheir entirety). Any one of these designs for the panel anchor membercan be used in the present invention.

Each panel anchor member 54 includes an elongate panel-penetratingportion 56 and an integral flange 58 that extends radially outwardlyfrom an end of the panel-penetrating portion. The flange 58 can be anysuitable shape, such as square, oval or the like, but in this embodimentis shown as circular. The layer of reinforcing material 16 and flange 58are disposed such that at least a portion of the layer of reinforcingmaterial is disposed between the exterior surface 60 the foam insulatingpanel and the flange of the panel anchor member 54, thereby attachingthe layer of reinforcing material to the foam insulating panel. Thepanel-penetrating portion 56 can be any suitable cross-sectional shape,such as square, round, oval or the like, but in this embodiment is shownas having a generally plus sign (“+”) cross-sectional shape. Thepanel-penetrating portion 56 comprises four leg members 62, 64, 66 (onlythree of the four legs are visible in FIG. 5) extending radiallyoutwardly from a central core member. The plus sign (“+”)cross-sectional shape of the panel-penetrating portion 56 prevents thepanel anchor member 54 from rotating around its longitudinal axis duringconcrete placement. Formed adjacent an end 68 of the panel anchor member54 opposite the flange 58 is a notch 70. The notch 70 is formed in eachof the four legs 62-66 adjacent the end 68 of the panel anchor member54. The notch 70 can be any shape, such as triangular, round, oval orthe like, but in this embodiment is shown as having a generallyrectangular shape (FIG. 5). Once plastic concrete is poured, the notch70 will capture a sufficient amount of concrete so that the anchormember 54 is solidly embedded in the concrete. The notch 70 provides aportion of the panel anchor member 54 having an effective reduceddiameter or dimension relative to the effective diameter or dimension ofthe four legs 62-64. Or, viewed another way, the four legs 62-64adjacent the end 68 have an effective larger diameter than the effectivediameter of the notch 70.

On each of the four legs 62-66 intermediate the flange 58 and the notch70 are a plurality of fins 72 projecting outwardly from each of thelegs. The fins 72 can be any suitable shape, such as round, but in thisembodiment are shown as generally rectangular and flaring outwardly fromthe legs 62-66 toward the flange 58. The fins 72 help retain the panelanchor member 54 after it is inserted in the foam insulating panel 14.This prevents the panel anchor member 54 from falling out of the foaminsulating panel 14 during transportation and setup.

The legs 62, 66 includes a U-shaped cutout 74 adjacent the end 68 of thepanel anchor member 54. The U-shaped cutout 74 is designed and adaptedto receive and hold a thin or small gauge rebar or wire mesh forreinforcing the structural concrete. The notch 74 is formed so that itcan hold reinforcing steel in place and at a desired position within theconcrete panel for optimal steel reinforcement placement. Of course, inaddition to the use of rebar, or in place of the use of rebar,reinforcing fibers, such as steel fibers, synthetic fibers or mineralfibers, such as Wollastonite, can be used. Many different types of steelfibers are known and can be used in the present invention, such as thosedisclosed in U.S. Pat. Nos. 6,235,108; 7,419,543 and 7,641,731 and PCTpatent application International Publication Nos. WO 2012/080326 and WO2012/080323 (the disclosures of which are incorporated herein byreference in their entireties). Particularly preferred steel fibers areDramix® 3D, 4D and 5D steel fibers available from Bekaert, Belgium andBekaert Corp., Marietta, Ga., USA. Plastic fibers can also be used, suchas those disclosed in U.S. Pat. Nos. 6,753,081; 6,569,525 and 5,628,822(the disclosures of which are incorporated herein by reference in theirentireties).

The foam insulating panel 14 is prepared by forming a plurality of holesin the foam insulating panel to receive the ends, such as the end 68 ofthe panel penetrating portion 56, of a plurality of panel anchor membersidentical to the panel anchor member 54. Holes (not shown) in thecomposite foam insulating panel 14 can be formed by conventionaldrilling, such as with a rotating drill bit, by water jets, by hotknives or by a saw knife. When the composite foam insulating panel 14includes a layer of reinforcing material 16 the layer of reinforcingmaterial is preferably adhered to the composite foam insulating panelbefore the holes are formed in the panel. It is also preferable to formthe holes in the composite foam insulating panel 14 after the moisturebarrier is applied to the bottom surface (or exterior surface) of thecomposite foam insulating panel. First, round holes are formed throughthe thickness of the foam insulating panel 14 extending from the uppersurface 75 to the bottom surface 60. The inner diameter of the holes isequal to the outer diameter of the central round core of the panelanchor member 54 so as to form a tight fit when the panel-penetratingportion 56 is inserted into each hole. Then, slots (not shown) radiatingoutwardly from the initial hole and spaced circumferentially 90 degreesfrom each other are drilled in the composite foam insulating panel 14 toaccommodate the four legs 62-66 of the panel anchor member 54 and toform a tight fit therewith. Alternately, a hole matching thecross-sectional shape of the end 68 of the panel anchor member 54,including the central round core and the legs, can be formed in thecomposite foam insulating panel 14 using a hot knife or a saw knife. Theholes formed in the composite foam insulating panel 14 extend from thebottom surface 60 to the upper surface 75, respectively, of thecomposite foam insulating panel so that the foam panel penetratingportion 56 of the panel anchor member 54 can be inserted completethrough the composite foam insulating panel, as shown in FIG. 5.

The foam insulating panel 14 is assembled by inserting the foam panelpenetrating portion 56 of the panel anchor member 54 through the hole(not shown) in the foam insulating panel 14, until the flange 58contacts the bottom surface 60 of the foam insulating panel and is flushwith the bottom surface 60 of the foam insulating panel (FIG. 5) or isflush with the layer of reinforcing layer 16, if present. It should benoted that when the layer of reinforcing material 16 is used on thebottom surface of the foam insulating panel 14, the layer of reinforcingmaterial is captured between the flange 58 of the panel anchor member 54and the bottom surface 60 of the foam insulating panel 14 (see forexample FIG. 5).

As shown in FIGS. 1-4, a plurality panel anchor members identical to thepanel anchor member 54 are positioned in spaced rows and columns acrossthe width and height of the foam insulating panel 14 (see FIGS. 2 and3). In the embodiment disclosed herein, the panel anchor members arespaced on 24 inch centers.

The panel anchor members, such as the panel anchor member 54, are usedto attach the foam insulating panel 14 to the concrete panel that willbe cast in the concrete form 10 on the top surface 75 of the foaminsulating panel. The panel anchor members, such as the panel anchor 54,are also used to optionally attach cladding systems to the exteriorsurface of the foam insulating panel 14. The panel anchor member 54 alsocaptures the layer of reinforcing material 16 between the flange 48 andthe exterior surface 60 of the foam insulating panel 14. The diameter ofthe flange 58 should therefore be as large as practical to maintain thepanel anchor member 54 in a vertical position when rebar is attached tothe panel anchor member, as described below, when plastic concrete isplaced in the form and to capture as much of the layer of reinforcingmaterial 16 between the flange 58 and the exterior surface 60 of thefoam insulating panel 14. It is found as a part of the present inventionthat a flange 58 having a diameter of approximately 2 to 4 inches,especially approximately 3 inches, is useful in the present invention.The diameter of the flange 58 should therefore be as large as practicalto support the anticipated weight of the cladding material that will beattached to the panel anchor member 54. Furthermore, the spacing betweenadjacent panel anchor members will vary depending on factors includingthe type of cladding that may optionally be attached to the panel anchormembers 54. However, depending on the desired type of exterior wallcladding, it is found as a part of the present invention that a spacingof adjacent panel anchor members 54 of approximately 6 inch to 24 inchcenters is useful in the present invention. By adhesively attaching thelayer of reinforcing material 16 to the exterior surface 60 of the foaminsulating panel 14, by capturing at least a portion of the layer ofreinforcing material between the flange 58 and the exterior surface 60of the foam insulating panel and by embedding at least a portion of thepanel penetrating portion 56 of the panel anchor member 54 in curedconcrete, the range of exterior cladding materials that can be attachedto the layer of reinforcing material is greatly expended and includes,but is not limited to, concrete, plaster, mortar, stucco, stone, brick,thin brick, tile and the like.

The thickness of the foam insulating panel 14 is also a factor that mustbe considered in designing the precast concrete panel in accordance withthe present invention and will vary depending on factors including theamount of insulation desired, the thickness of the concrete panel, thethickness of the structural reinforcing elements and the dimensions ofthe concrete panel. However, the thickness of the foam insulating panelis not uniform. The foam insulating panel 14 has a thickness “A” at thechannels 18-26, 36 and the half-channels 28-34 and a thickness “B” atthe elevated islands 38-48 and 50-52 (FIG. 4). The difference in thethickness of the foam insulating panel at “A” and at “B” is designatedas “C” (FIG. 4). The thicknesses at both “A” and “B” can be variedindependently depending on design criteria of the thickness of thereinforcing element and the desired amount of minimum insulation at thethickness “A”. There is no maximum thickness for the foam insulatingpanel 14 that can be used in the present invention. The maximumthickness is only dictated by economics and/or ease of handing. However,it is found as a part of the present invention that the thickness forthe foam insulating panel 14 at “A” should not be less than 1 inch,preferably not be less than 1.5 inches, more preferably not less than 3inches, especially approximately 1.5 inches to approximately 12 inches.The thickness of the foam insulating panel 14 at “A” is preferablyapproximately 1.5 inches, more preferably approximately 3 inches, mostpreferably approximately 4 inches, especially approximately 5 inches,more especially approximately 6 inches. The thickness for the foaminsulating panel 14 at “B” preferably should not be less than 2 inches,more preferably not less than 3 inches, most preferably not less than 4inches, especially not less than 5 inches, more especially not less than6 inches, most especially approximately 3 inches to approximately 12inches. The thickness of the foam insulating panel 14 at “B” isapproximately 2 inches, preferably approximately 3 inches, morepreferably approximately 4 inches, most preferably approximately 5inches, especially approximately 6 inches, more especially approximately7 inches, most especially approximately 8 inches.

Use of the present invention will now be considered. It is anticipatedthat the foam insulating panel 14 with the panel anchor members 54installed in it will be preassembled at a remote location andtransported to a job site. Also, in many cases the foam insulating panel14 is precut and predrilled at a factory and then delivered to a jobsite with or without the layer of reinforcing material 16 on the foaminsulating panel. Then, all panel anchor members 54 can be installed inthe foam insulating panel 14 on site. In another embodiment the precastconcrete panels can be cast at a precast plant where all of the abovecan be assembled on a casting table, in a battery mold, in a form withpre-tensioned steel cables or any other suitable surface. The foaminsulating panel 14 is then place on a flat horizontal surface, such ason the flat surface 13 of the concrete slab 12. The foam insulatingpanel 14 forms a bottom surface, or at least a portion of the bottomsurface, of the insulated concrete form 10 and has the exact desireddimensions of the finished concrete panel, which in this case isillustrated as being 20 feet by 40 feet, except for an optional smalloffset at the peripheral edges (See FIG. 5).

After the foam insulating panel 14 is positioned as shown in FIG. 1, aconventional wood or metal form is constructed around the peripheraledges of the foam insulating panel. Specifically, as shown in FIGS. 1, 2and 3, a longitudinal side form member 76 is disposed against the rightlongitudinal edge of the foam insulating panel 14. A transverse sideform member 78 is disposed against the upper lateral edge of the foaminsulating panel 14. A longitudinal side form member 80 is disposedagainst the left longitudinal exterior edge of the foam insulating panel14. And, a transverse side form member 82 is disposed against the lowerlateral edge of the foam insulating panel 14. The side form members76-82 are joined together in a manner well known in the art. Althoughthis embodiment has been disclosed as positioning the foam insulatingpanel 14 and then constructing the side frame members 76-82, the presentinvention also contemplates constructing the side form members first andthen placing the foam insulating panel 14 within the side frame members.If the side frame members 76-82 are constructed first, it may benecessary to trim the foam insulating panel 14 to fit. This can easilybe done with a saw, a knife blade or preferably with a hot knife.

As can be seen in FIGS. 1-4, when plastic concrete 84 is placed on thefoam insulating panel 14, it fills the channels 18-26, 36 andhalf-channels 28-34 and forms a layer of uniform thickness above theelevated islands 38-48 and 50-52. However, since the concrete is thickerwhere the channels 18-26, 36 and half-channels 28-34 are formed, thatthicker concrete then becomes a structural reinforcing element, such asa column, beam or rib. For example, as shown in FIGS. 2-4, a transverseperipheral structural reinforcing element, such as a column 86, isformed in the cavity defined by the half channel 28 and the side formmember 82. Similarly, a longitudinal peripheral structural reinforcingelement, such as a beam 88, is formed in the cavity defined by the halfchannel 34 and the side form member 80. Additionally, five transversestructural reinforcing elements, such as columns 90, 92, 94, 96, 98, areformed in the channels 18-26 (FIG. 2) and a longitudinal centralstructural reinforcing element, such as a beam 100, is formed in thechannel 36 (FIG. 3). Furthermore, a transverse peripheral structuralreinforcing element, such as a column 102, is formed in the cavitydefined by the half channel 30 and the side form member 78 (FIG. 2).Similarly, a longitudinal peripheral structural reinforcing member, suchas a column 104, is formed in the cavity defined by the half channel 32and the side form member 76 (FIG. 3).

As shown in FIGS. 2-4, the thickness of the concrete 84 is not uniform.The concrete 84 has a thickness “D” at the elevated islands 38-48 and50-52 and a thickness “E” at the channels 18-26, 36 and half-channels28-34. The height of the side form members 76-82 is selected such thatit is equal to the thickness of the foam insulating panel 14 at the halfchannels 28-34; i.e., thickness “A”, plus the desired thickness of thebeams 88, 100, 104 and columns 86, 90-98, 102; i.e., thickness “E”. Forexample, if the foam insulating panel 14 is three inches thick (“A”) atthe channels 18-26, 36 and half-channels 28-34 and the thickness of thebeams 88, 100, 104 and columns 86, 90-98, 102 is six inches (“E”), theside form members 76-82 will be nine inches high. With these dimensions,the thickness of the concrete above the elevated islands 38-48 and 50-52is three inches (“D”). The thicknesses of these different portions ofthe precast concrete panel can be adjusted by changing the difference(“C”) in the thickness of the foam insulating panel 14 at the channels18-26, 36 and half-channels 28-34 and at the elevated islands 38-48 and50-52. Further adjustments can be made by changing the thickness (“D”)of the concrete 84 above the elevated islands 38-48 and 50-52.

The channels in the foam insulating panel 14, such as the channels18-26, 36 and half-channels 28-34, are sized (for width and thickness)and shaped to provide structural reinforcement to the finished concretepanel or slab so that it has improved strength against deflection duringraising of the panel to a vertical position and against anticipated windloads or other loads. Specifically, channels are provided in the foaminsulating panel 14 so as to provide structural reinforcing elements,such as columns, beams or ribs, at the panel locations where the maximumloads and stresses are located, such as around the periphery of theconcrete panel and/or where roof trusses or floor slab connections maybe located. In the embodiment shown, such peripheral structuralreinforcing columns, beams or ribs comprise the columns 86, 102 and thebeams 88, 104. It is also preferred that the concrete panel include atleast one intermediate horizontal reinforcing beams, such as the beam100, to minimize lateral deflection and improve load bearing capacityand any other desired structural property. The size and the shape of thereinforcing columns, beams and ribs are dictated by the structuralrequirements of individual panel designs based upon the anticipatedloads and stresses. However, the reinforcing columns, beams or ribs arepreferably at least 25% thicker than the portion of the concrete panelbetween the reinforcing columns, beams or ribs; i.e., the thickness “E”is at least 25% thicker than the thickness “D”; preferably at least 50%thicker, more preferably at least 75% thicker, most preferably at least100% thicker. The width of the reinforcing columns, beams or ribs aredictated by design requirements. However, the reinforcing columns, beamsor ribs are at least 4 inches wide, preferably at least 6 inches wide,more preferably at least 8 inches wide, most preferably at least 10inches wide.

As stated above, each of the panel anchor members, such as the panelanchor member 54, includes a U-shaped portion 74 extending upwardlyadjacent the end 68. The U-shaped portion 74 is sized and shaped as arebar chair to receive and retain an elongate round steel rebar, such asthe rebar 108 or wire mesh. The U-shaped portion 74 has a degree ofresilience to it so that the rebar 108 can be pushed or laid into theU-shaped portion and the U-shaped portion will hold the rebar withsufficient force such that the rebar will not be easily dislodged fromthe U-shaped portion when plastic concrete 84 is poured into theconcrete form 10 and on top of the horizontal foam insulating panel 14.The U-shaped portion 74 of the panel anchor member 54 is aligned withthe other U-shaped portions of the other panel anchor members in thesame row of panel anchor members, so that the same piece of rebar 108 orwire mesh can be attached to the U-shaped portions of the other panelanchor members (see FIG. 1). Thus, aligned rows of panel anchor members54 provide aligned rows of U-shaped portions 74, such that additionalrows of rebar parallel to the rebar 108, such as the rebar 110, 112, ofa desired length can be attached to the rows of panel anchor members.Crossing columns of rebar, such as the rebar 114, 116, are laid on topof the rows of rebar, such as the rebar 108-112 to form a conventionalrebar grid. Where the columns and rows of rebar intersect, such as therebar 108 and the rebar 114 (FIGS. 1 and 5), the rebar can be tiedtogether with wire or plastic ties (not shown) in any conventionalmanner known in the art. The panel anchor members, such as the panelanchor member 54, are designed such that the distance from the flange 58to the U-shaped portion 74 positions the rebar, such as the rebar 108,at approximately the mid-point of the thickness of the concrete abovethe elevated islands 38-48 and 50-52 or at any other specified distanceor point from the exterior concrete surface. Thus, the panel anchormembers 54 will automatically position the rebar grid at the properdepth for the precast concrete panel being constructed, as required bystructural design calculations. Of course additional rebar, such as therebar 118, 120 (FIG. 4), can be included in the beams 88, 100, 104 andcolumns 86, 90-98, 102 to provide additional reinforcement as designrequirements may require for the maximum stresses or loads anticipatedat such locations.

After the rebar grid, such as the rebar 108-120, or wire mesh isconstructed in the insulated concrete form 10, the form is filled withplastic concrete 84. Sufficient plastic concrete 84 is placed in theform such that the plastic concrete in the form reaches the top 122 ofthe side form members 76-82. Embeds and/or inserts are attached to theedge or the face of any of the structural reinforcement elements, suchas the side forms member 76-82 or to the rebar grid, as needed ordesired. The inserts can be threaded or have connection hooks, loops orany other attachment type well known in the art. Such inserts are usedfor raising the panel from a horizontal position to a vertical position,for loading onto a flat bed track, or for hoisting the panel into place,such as for high-rise building exterior concrete panels. The type, sizeand placement of such embeds and/or inserts are not important to thepresent invention and are determined by design calculation or otherdesign criteria. Especially useful is that in multistory construction,threaded inserts can be placed at spaced interval in the longitudinalintermediate structural member 100 for attachment of an intermediatefloor system (not shown). Likewise inserts can be attached to the faceof the structural members 88 or 104 or to the edge thereof for rooftruss connections and the like. Especially useful is that the insertsare located at the intersection of the longitudinal and the transversal(vertical and horizontal) structural reinforcing elements in such a wayas to most effectively distribute the stress and loads within thestructure. For example, FIG. 4 shows a female threaded insert with areinforcement loop 124 in the concrete and an embedment 126. The topsurface 128 of the plastic concrete 84 is then finished in any desiredconventional manner, such as by troweling, or to provide other types ofarchitectural finishes or patterns.

After the plastic concrete 84 in the form 10 has been finished, a layerof insulating material 130 optionally is placed on the top 122 of theside form members 76-82 and the top surface 128 of the finished plasticconcrete 84, as shown in FIGS. 1, 6 and 7. The layer of insulatingmaterial 130 can be made from the same material as the foam insulatingpanel 14 that forms the bottom of the concrete form 10. However, thelayer of insulating material 130 is preferably a concrete insulatingblanket or an electrically heated concrete blanket. If the layer ofinsulating material 130 is made from polystyrene, it preferably is atleast 0.5 inches thick; more preferably at least 1 inch thick,especially at least 2 inches thick; more especially at least 3 inchesthick; most especially, at least 4 inches thick. If the layer ofinsulating material 120 is made from expanded polystyrene foam, itpreferably is approximately 0.5 inches thick; preferably approximately 1inch thick; more preferably approximately 2 inches thick; especiallyapproximately 3 inches thick; most especially approximately 4 inchesthick. If the layer of insulating material 120 is made from a materialother than polystyrene, it should have insulating properties equivalentto at least 0.5 inches of expanded polystyrene foam; preferablyapproximately 1 inch to approximately 8 inches of expanded polystyrenefoam; more preferably at least 1 inch of expanded polystyrene foam;especially at least 2 inches of expanded polystyrene foam; moreespecially at least 3 inches of expanded polystyrene foam; mostespecially, at least 4 inches of expanded polystyrene foam. If the layerof insulating material 120 is made from a material other than expandedpolystyrene foam, it should have insulating properties equivalent toapproximately 0.5 inch thick of expanded polystyrene; approximately 1inch thick; preferably approximately 2 inches thick; especiallyapproximately 3 inches thick; most especially approximately 4 inchesthick. Expanded polystyrene foam has an R-value of approximately 4 to 5per inch thickness. Therefore, the layer of insulating material 120should have an R-value of greater than 1.5, greater than 4, preferablygreater than 10, more preferably greater than 15, especially greaterthan 20. The layer of insulating material 120 preferably has an R-valueof approximately 5 to approximately 40; more preferably betweenapproximately 10 to approximately 40; especially approximately 15 toapproximately 40; more especially approximately 20 to approximately 40.The layer of insulating material 120 preferably has an R-value ofapproximately 5, more preferably approximately 10, especiallyapproximately 15, most preferably approximately 20.

The objective of the present invention is to insulate the plasticconcrete 84 within the form 10 as completely as possible; i.e., on allsides. As can be seen in FIGS. 6 and 7, the plastic concrete 84 in theconcrete form 10 is insulated on both the top, the bottom and on allsides. Thus, the plastic concrete 84 in the form 10 is completelyencased or surrounded in insulating material by the bottom foaminsulating panel 14 and on the top and the sides by the layer ofinsulating material 130.

When the layer of insulating material 130 is a concrete insulatingblanket or an electrically heated concrete blanket, it is draped overthe top surface 128 of the plastic concrete 84, the tops 122 of the sideform members 76-82 and down the sides of the form; i.e., around the sideform members and down to the surface 13 of the concrete slab 12. Again,the objective is to completely surround the plastic concrete 84 withinsulating material.

A concrete insulating blanket is typically made from a tarp materialfilled with polyethylene or polypropylene foam. Suitable concreteinsulating blankets are commercially available under the designationMicro Foam from Pregis, Lake Forest, Ill. The concrete insulatingblanket can also be an electrically heated concrete insulating blanket.Such electrically heated concrete insulating blankets have been used inhighway construction in the northern United States to prevent plasticconcrete from freezing in winter weather or to thaw frozen ground.Suitable electrically heated concrete insulating blankets arecommercially available under the designation Powerblanket from PowerBlanket LLC, Salt Lake City, Utah Concrete insulating blankets haveadvantages over the use of foam insulating panels, such as the foaminsulating panel 14, in that the concrete insulating blankets areflexible and can be rolled up for easier transportation. An electricallyheated concrete insulating blanket also has the advantage to being ableto provide additional heat to the curing concrete in order to acceleratethe curing or maturing process. The concrete insulating blanket (or theelectrically heated concrete insulating blanket) should have insulatingproperties equivalent to the layer of insulating material 130 as setforth above.

If the layer of insulating material 130 is an electrically heatedconcrete blanket or an electrically heated concrete form, it should bedesigned and operated in the same manner as the electrically heatedblanket or the electrically heated concrete form disclosed inapplicant's co-pending patent application Ser. No. 13/626,075 filed Sep.25, 2012 (the disclosure of which is incorporated herein by reference inits entirety). Thus, if an electrically heated concrete blanket or anelectrically heated concrete form is used for the layer of insulatingmaterial 130, the concrete 84 is preferably cured according to apredetermined temperature profile, in the manner disclosed inapplicant's co-pending patent application Ser. No. 13/626,075 filed Sep.25, 2012 (the disclosure of which is incorporated herein by reference inits entirety).

The layer of insulating material 130 can also be made from a refractoryinsulating material, such as a refractory blanket or a refractory board.Refractory insulating material is typically used to line hightemperature furnaces or to insulate high temperature pipes. Refractoryinsulating material is typically made from ceramic fibers made frommaterials including, but not limited to, silica, silicon carbide,alumina, aluminum silicate, aluminum oxide, zirconia, calcium silicate;glass fibers, mineral wool fibers, and fireclay. Refractory insulatingmaterial is commercially available in bulk fiber, foam, blanket, board,felt and paper form. Refractory insulation is commercially available inblanket form as Fiberfrax Durablanket® insulation blanket from Unifrax ILLC, Niagara Falls, N.Y., USA and RSI4-Blank and RSI8-Blank fromRefractory Specialties Incorporated, Sebring, Ohio, USA. Refractoryinsulation is commercially available in board form as Duraboard® fromUnifrax I LLC, Niagara Falls, N.Y., USA and CS85, Marinite and Transiteboards from BNZ Materials Inc., Littleton, Colo., USA. The refractoryinsulating material can be any thickness that provides the desiredinsulating properties, as set forth above. There is no upper limit onthe thickness of the refractory insulating material; this is usuallydictated by economics and/or ease of handling. However, refractoryinsulating material useful in the present invention can range from 1/64inch to approximately 2 inches. Similarly, ceramic fiber materialsincluding, but not limited to, silica, silicon carbide, alumina,aluminum silicate, aluminum oxide, zirconia, calcium silicate; glassfibers, mineral wool fibers, Wollastonite and fireclay, can be suspendedin a polymer, such as polyurethane, latex, or epoxy, and used as acoating to create a refractory insulating material layer, for examplecovering, or substantially covering, one of the primary surfaces of aform or mold, such as a battery mold, for the insulated concrete panelof the present invention. Ceramic fibers in a polymer binder or foam arecommercially available as Super Therm®, Epoxotherm and HPC Coating fromSuperior Products, II, Inc., Weston, Fla., USA. Alternatively, the topinsulating material 130 can be a panel made of two reinforcing sheets(not shown) held together by a compound made of ceramic fibers suspendedin a polymer binder or foam.

Of course, for certain applications, it may be desirable to omit the useof the layer of insulating material 130 on the top and sides of theform; i.e., omit the use of the top and side foam insulating panels orthe use of the concrete insulating blanket (or the electrically heatedconcrete insulating blanket). In other situations, it may be desirableto place a concrete insulating blanket or an electrically heatedconcrete insulating blanket on top of the top and side foam insulatingpanels, if used for the layer of insulating material 130.

The uncured concrete 84 is kept in the form 10 for a time sufficient forthe concrete to achieve sufficient strength, such as sufficientcompressive strength, so that the partially cured concrete panel can bemoved or raised without breaking, suffering structural damage orcracking. The time necessary for the uncured concrete 84 to achieve adesired amount or degree of cure will vary depending on many factors,including the type of concrete mix used, ambient temperatures, thicknessof the concrete, and the like. However, the uncured concrete 84 willgenerally achieve sufficient strength within approximately four hours toseven days. By using the layer of insulating material 130 (orelectrically heated insulating blanket or electrically heated concreteform) in accordance with the present invention, the uncured concrete 84in the form 10 will cure faster and will achieve early strength morequickly than prior art systems. The layer of insulating material 130 (orelectrically heated insulating blanket or electrically heated concreteform) in accordance with the present invention also results in lessplastic concrete shrinkage, thereby reducing cracking of the finishedconcrete. These benefits make the precast concrete panel in accordancewith the present invention stronger and allow the panel to be moved orraised earlier than prior art systems. By retaining the water in theconcrete mix within the concrete form 10 and since that space isinsulated by the layer of insulating material 130 and the foaminsulating panel 14, the heat of hydration of the curing concrete isretained within the insulated concrete form and sufficient water ispresent such that the concrete will achieve its maximum potentialstrength faster, thereby producing stronger concrete (in terms of bothearly strength and ultimate strength).

After the uncured concrete 84 has achieved a desired amount or degree ofcure, the insulating material 130 is removed, if present, and the sideform members 76-82 are removed (FIGS. 8-10), thus leaving a reinforcedconcrete panel 200 (FIG. 11) and an integrally attached foam insulatingpanel 14. Since the concrete 84 is at lease partially cured, the panelanchor members, such as the panel anchor members 54, are securelyanchored in the concrete panel 200. The foam insulating panel 14 istherefore mechanically attached to the concrete panel 200 by the panelanchors members 54 and by an adhesive bond between the foam insulatingpanel 14 and the concrete 84; i.e., as the uncured concrete cures, itforms a strong adhesive bond with the foam insulating panel. Thus, theconcrete panel 200 is both mechanically attached to the foam insulatingpanel 14 by the panel anchor members 54 and physically attached by theadhesive bond of the concrete across the entire surface of the foaminsulating panel. This large surface area provides a substantial andstrong connection between the foam insulating panel 14 and the concretepanel 200.

Precast plants make use of steam curing rooms. In one disclosedembodiment, the insulating material 130 can be kept in place for only asufficient amount of time for the concrete to achieve the necessaryamount of hardness before it can be stripped from the form or mold andthe concrete panel and attached foam insulating panel moved into aconventional steam curing room. Since there is no bond between thebottom of the foam panel and the casting surface (table) it rests on,the concrete panel can be easily moved and stored on shelves in a steamcuring room until it has achieved the necessary hydration and strength.Since only the side form elements have to be stripped from the entireconcrete assembly, it can easily be moved on a conveyor belt system fromthe casting area into the steam curing area. The casting and curing areacan be efficiently integrated with a conveyor, delivery and steam curingstorage area.

After the concrete panel 200 has achieved a desired amount or degree ofcure, an exterior non-structural (i.e., decorative) architectural layer202 can be applied to the surface of the foam insulating panel 14opposite the concrete panel; i.e., on the layer of reinforcing material16, if present (FIG. 10). The exterior architectural layer 202 can beapplied, for example at a manufacturing facility or it can be appliedafter the concrete panel 200 and attached foam insulating panel 14 areerected to a vertical position at a job site and attached to a buildingstructure or other structure (not shown).

The exterior architectural layer 202 can be applied by any suitablemeans, such as by spraying, hand troweling, dry casting, wet casting orby extrusion to the necessary thickness, depending on the material andthe thickness of the exterior decorative layer. The exteriorarchitectural layer 202 can be made of conventional concrete, mortar,stucco, synthetic stucco, plaster or any other cementitious material,cementitious polymer modified material or polymer coatings. Aparticularly preferred exterior architectural layer 202 is a layer ofpolymer modified cementitious material, such as polymer modifiedconcrete, polymer modified plaster or polymer modified mortar, withdecorative aggregate only partially embedded into the layer of polymermodified plaster. The decorative aggregate particles can be anydecorative and/or colorful stone, semi-precious stone, quartz, granite,basalt, marble, stone pebbles, glass or shells. The decorative aggregateparticles can be made from stone including, but not limited to,amethyst, azul bahia, azul macaubas, foxite, glimmer, honey onyx, greenonyx, sodalite, green jade, pink quartz, white quartz, and orangecalcite. The decorative aggregate particles can be made from crushedglass including, but not limited to, recycled clear glass, recycledmirror glass, recycled clear plate glass, recycled cobalt blue glass,recycled mixed plate glass, and recycled black glass. The decorativeaggregate particles can be made from recycled aggregate including, butnot limited to, recycled amber, recycled concrete and recycledporcelain. The decorative aggregate particles can be made fromnon-recycled glass including, but not limited to, artificially coloredglass, reflective glass, transparent glass, opaque glass, frosted glassand coated glass. The decorative aggregate particles can be made fromtumbled glass including, but not limited to, jelly bean and glass beads.Decorative aggregate can be obtained from Arim Inc., Teaneck, N.J., USA.The decorative aggregate particles can be any suitable size, butpreferably are size #000 (passes mesh 16, retained on mesh 25) to size#3 (½ inch to ⅜ inch), more preferably size #00 (passes mesh 10,retained mesh 16) to size #2 (⅜ inch to ¼inch) and most preferably size#00 (passes mesh 10, retained mesh 16) to size #1 (¼inch to ⅛ inch). Thedecorative aggregate particles preferably have irregular, random shapes.However, for certain applications it may be desirable for the aggregateparticles to have uniform shapes, such as are obtained by tumbling theaggregate, for example jelly bean shaped or bead shaped. The decorativeaggregate can be partially embedded in the layer of polymer modifiedcementitious material by any suitable method, such as by broadcastinginto the layer of polymer modified cementitious material followed bypushing the decorative aggregate particles partially into the layer ofpolymer modified cementitious material by using a roller. However, thelayer of decorative aggregate is preferably formed in the layer ofpolymer modified cementitious material by blowing decorative aggregateparticles into the layer of polymer modified cementitious material usingcompressed air. After blowing the decorative aggregate particles intothe layer of polymer modified cementitious material if additionalembedment of the decorative aggregate particles in the layer of polymermodified cementitious material is necessary, the decorative aggregateparticles can be pushed partially into the layer of polymer modifiedcementitious material by using a roller.

The exterior architectural layer 202 can be sprayed or have anintegrated color pigment and/or it can have any type of architecturaltexture or color finish. To provide greater flexural strength and impactresistance, a particularly preferred material for the exteriorarchitectural layer 202 is polymer modified concrete, polymer modifiedcement plaster, polymer modified geopolymer or polymer modified mortar.Polymer modified concrete, polymer modified cement plaster, polymermodified geopolymer or polymer modified mortar is known in the art andcomprises a conventional concrete, plaster, geopolymer or mortar mix towhich a polymer is added in a polymer-to-cement ratio of 0.1% to 50% byweight, preferably 0.1% to 25% by weight, more preferably approximately1% to 25% by weight, most preferably approximately 5% to approximately20% by weight. Polymer modified concrete can be made using the polymeramounts shown above in any of the concrete formulations shown below.Polymers suitable for addition to concrete, plaster or mortar mixes comein many different types: thermoplastic polymers, thermosetting polymers,elastomeric polymers, latex polymers and redispersible polymer powders.A preferred thermoplastic polymer is an acrylic polymer. Latex polymerscan be classified as thermoplastic polymers or elastomeric polymers.Latex thermoplastic polymers include, but are not limited to,poly(styrene-butyl acrylate); vinyl acetate-type copolymers; e.g.,poly(ethyl-vinyl acetate) (EVA); polyacrylic ester (PAE); polyvinylacetate (PVAC); and polyvinylidene chloride (PVDC). Latex elastomericpolymers include, but are not limited to, styrene-butadiene rubber(SBR); nitrile butadiene rubber (NBR); natural rubber (NR);polychloroprene rubber (CR) or Neoprene; polyvinyl alcohol; and methylcellulose. Redispersible polymer powders can also be classified asthermoplastic polymers or elastomeric polymers. Redispersiblethermoplastic polymer powders include, but are not limited to,polyacrylic ester (PAE); e.g., poly(methyl methacrylate-butyl acrylate);poly(styrene-acrylic ester) (SAE); poly(vinyl acetate-vinyl versatate)(VA/VeoVa); and poly(ethylene-vinyl acetate) (EVA). Redispersibleelastomeric polymer powders include, but are not limited to,styrene-butadiene rubber (SBR). Preferred polymers for modifying theconcrete, plaster or mortar mixes of the present invention arepolycarboxylates. A particularly preferred polymer modified concrete,plaster or mortar for use as the exterior architectural layer 202 isdisclosed in U.S. Pat. No. 7,714,058 (the disclosure of which isincorporated herein by reference in its entirety). Geopolymers aregenerally formed by reaction of an aluminosilicate powder with analkaline silicate solution at roughly ambient conditions. Metakaolin isa commonly used starting material for synthesis of geopolymers, and isgenerated by thermal activation of kaolinite clay. Geopolymers can alsobe made from sources of pozzolanic materials, such as lava, fly ash fromcoal, slag, rice husk ash and combinations thereof.

It is specifically contemplated that the cementitious-based materialfrom which the exterior architectural layer 202 is made can includereinforcing fibers made from material including, but not limited to,steel, plastic polymers, glass, basalt, Wollastonite, carbon, and thelike. The use of reinforcing fiber in the exterior architectural layer202 made from polymer modified concrete, polymer modified mortar orpolymer modified plaster provide the layer of cementitious material withimproved flexural strength, as well as improved impact resistance andblast resistance.

Wollastonite can be used in the exterior architectural layer 202 toincrease compressive and flexural strength as well as impact resistance.Also, Wollastonite can improve resistance to heat transmission and addfire resistance to the exterior plaster. Therefore the coating canobtain fire resistance properties as well as improved energy efficiencyproperties. A fire resistant material over the exterior face of the foamcan increase the fire rating of the wall assembly by delaying themelting of the foam. Increased resistance to heat transmission will alsoincrease the building energy efficiency and therefore lower energy cost,such as heating and cooling expenses.

For a relatively thin and strong exterior architectural layer 202 madefrom relatively light material, such as a polymer, for example anacrylic polymer base coat; polymer modified concrete; cement plaster;geopolymer or mortar, the exterior coating can be applied with thecomposite panel in a vertical orientation. This can be done by raisingthe concrete panel 200 and attached foam insulating panel 14 to avertical orientation. The exterior architectural layer 202 can then beapplied to the exterior surface of the foam insulating panel 14 and thelayer of reinforcing material 16, if present, by any suitable method,such as by spraying, by hand troweling or by extrusion. For example, apolymer, for example an acrylic polymer base coat; polymer modifiedconcrete; cement plaster; geopolymer or mortar is applied to theexterior surface of the foam insulating panel 14 and the layer ofreinforcing material 16, if present, by spraying to a desired thickness,such as approximately 1/16 inch to approximately 2 inches; preferablyapproximately 1/16 inch, approximately ⅛, preferably approximately ¼inch, preferably approximately 0.5 inches, preferably approximately 0.75inches, preferably approximately 1 inch, preferably approximately 1.25inches, preferably approximately 1.5 inches, preferably approximately1.75 inches and preferably approximately 2 inches. The exteriorarchitectural layer 202 is more preferably approximately 1/16 inch toapproximately 1 inch. The polymer modified concrete, cement plaster,geopolymer or mortar is preferably applied to the exterior surface ofthe foam insulating panel 14 and the layer of reinforcing material 16,if present, by extrusion to a desired thickness, preferablyapproximately ⅛ inch to approximately 1.75 inches. Other suitablecoatings for use as the thin exterior architectural layer 202 include,but are not limited to, a cementitious or an acrylic EIFS base coat,such as Parex 121 base coat mixed with portland cement (or dry bagversion); a 100% acrylic polymer base coat, such as Parex ABC-N1 basecoat; a color integrated acrylic finish coat, such as Parex DPR acrylicfinish coat; a multicolor finish made of colored beads mixed with aclear polymer binder, such as Parex Cerastone or any type of finishcoating, such as Parex Specialty finishes.

The sprayed or extruded polymer, polymer modified concrete, cementplaster, polymer modified cement plaster, geopolymer or mortar on thefoam insulating panel 14 and the layer of reinforcing material 16, ifpresent, is then smoothed with a hand trowel to form an even, smoothsurface for the exterior architectural layer 202 or left in it's naturalextruded state or sprayed texture. The exterior architectural layer 202is then allowed to cure sufficiently so that the concrete panel 200 canbe moved without causing cracking or damage to the exterior decorativelayer. If acceleration of the curing process is desired or needed, theexterior architectural layer 202 is wrapped with a layer of insulatingmaterial, such as using the layer of insulating material 130 in the samemanner as described above for the plastic concrete 84. Alternatively,the exterior architectural layer 202 is enclosed by an electricallyheated concrete blanket or by an electrically heated concrete form andthe exterior coating is cured according to a predetermined temperatureprofile, in the manner disclosed in applicant's co-pending patentapplication Ser. No. 13/626,075 filed Sep. 25, 2012 (the disclosure ofwhich is incorporated herein by reference in its entirety). Similarly,the entire assembly; i.e., concrete panel 200, foam insulating panel 14and exterior architectural layer 202, can be placed inside a steamcuring room, as previously described.

If a thicker and/or heavier layer or material is used for the exteriorarchitectural layer 202, the concrete panel 200 is then inverted fromthe position shown in FIGS. 1-4 to the position shown in FIGS. 9-10, sothat the concrete panel 200 is resting on the casting surface 13 and thelayer of reinforcing material 16, if present, is facing upward, as shownin FIG. 10. The concrete panel 200 is inverted using techniques andapparatus that are well known in the art. The exterior architecturallayer 202 can then be applied to the foam insulating panel 14 and layerof reinforcing material 16, if present, in the same manner as describedabove for the plastic concrete 84. Side form members 204, 206, 208, 210can be used, if necessary.

Use of polymer modified concrete, polymer modified cement plaster,geopolymer or mortar for the exterior architectural layer 202 withstandsfar greater flexural stresses, and it eliminates the internalreinforcing and pre-stressed cables associated with other types ofsandwich panels. Yet another benefit of using a polymer modifiedconcrete, polymer modified cement plaster, polymer modified stucco,polymer modified geopolymer or polymer modified mortar is the alkalinityof the cementitious material is reduced compared to conventionalconcrete which allows for use of lath and meshes made from variousmineral or synthetic fibers as reinforcement for the exteriorarchitectural layer 202. All of the foregoing effectively reduces thethickness of the exterior architectural layer 202 to a minimum possiblethickness, as required by specific applications and budgets.

The thickness of the exterior architectural layer 202 is substantiallythinner than the concrete panel 200 at its thinnest portion; i.e., at“D”. The exterior architectural layer 202 is less than 50% of thethickness of the concrete panel 200; preferably, less than 25% of thethickness of the concrete panel; more preferably, less than 10% of thethickness of the concrete panel; most preferably, less than 5% of thethickness of the concrete panel at its thinnest portion. Since theexterior architectural layer 202 is much thinner than the concrete panel200, the overall weight of the composite panel of the present inventionis much less than conventional concrete panels. It also eliminates theneed for strong ties between the interior and exterior wythes, such asrequired in the prior art T-Mass and the Carboncast concrete panels. Byusing a relatively thin, lightweight layer for the exteriorarchitectural layer 202, a bond breaker between the foam insulatingpanel 14 and the concrete panel 200 is not required. In fact, it isspecifically contemplated as a part of the present invention that anadhesive bond is formed between the concrete panel 200 and the foaminsulating panel 14 and between the exterior architectural layer 202 andthe foam insulating panel. Also, the bond between the concrete panel 200and the foam insulating panel 14 and the exterior architectural layer202 and the foam insulating panel, in conjunction with the mechanicalconnection provided by the panel anchor members 54 and the layer ofreinforcing material 16 create a much stronger composite insulatedconcrete panel and yet more flexible to certain deflection. Furthermore,since the exterior architectural layer 202 is so thin, the exteriorthermal mass is relatively small which makes the overall energyefficiency of the composite insulated concrete panel of the presentinvention far greater than prior art concrete panels.

The exterior architectural layer 202 is kept in the form (if cast) for atime sufficient for the concrete to achieve a desired amount of cure. Ifthe exterior architectural layer 202 is sprayed, hand troweled orextruded, then no form is necessary. When sprayed, hand troweled orextruded, the concrete panel 200 can be horizontal or vertical dependingon available space and preference. If other types of materials are used,such as polymer modified concrete, polymer modified cement plaster,polymer modified stucco, acrylic base coat and finishes, geopolymer ormortar or polymers, there may be no need to keep the material under thelayer of insulating material 130. The time necessary for the polymermodified concrete, polymer modified cement plaster, polymer modifiedgeopolymer or polymer modified mortar of the exterior architecturallayer 202 to achieve a desired amount or degree of cure will varydepending on many factors, including the material used, the type ofconcrete mix used, ambient temperatures, thickness of the exteriorcoating, and the like. However, the exterior architectural layer 202will generally achieve sufficient strength within approximately one hourto seven days. By using the layer of insulating material 130 (or theelectrically heated insulating blanket or electrically heated form) inaccordance with the present invention, the concrete, plaster or mortarin the form will set faster and hydrate faster and will achieve earlyconcrete, plaster or mortar strength more quickly than prior artsystems. The electrically heated blanket or electrically heated form inaccordance with the present invention also results in less plasticconcrete, plaster or mortar shrinkage, thereby reducing cracking of thefinished concrete, plaster or mortar. Using a steam curing room has asimilar effect on the curing of the polymer modified concrete, cementplaster, geopolymer or mortar as any of the other enhanced curingsystems and methods mentioned above. These benefits make the precastconcrete panel in accordance with the present invention stronger andallow the panel to be used earlier than prior art systems. By retainingthe water in the concrete mix within the insulated concrete form andsince that space is insulated by the foam insulating panel 14 and layerof insulating material 130, the heat of hydration is retained within theinsulated concrete form such that the concrete, plaster or mortar mix ofthe exterior architectural layer 202 will achieve its maximum potentialstrength and rigidity earlier and faster, thereby producing a strongerconcrete panel.

After the exterior architectural layer 202 has achieved a desired amountor degree of cure, the layer of insulating material 130 is removed, ifpresent, and the side form members 204-210 are removed, if present. Theresulting product is a composite reinforced concrete panel 212 thatcomprises the concrete panel 200, the attached foam insulating panel 14and the exterior architectural layer 202 (FIG. 11). The compositereinforced concrete panel 212 is then ready to use. As shown in FIG. 11,the composite reinforced concrete panel 212 is raised from a horizontalposition to a vertical position and positioned on the surface 13 of theconcrete slab 12 to form a wall section of a building or other structure(not shown).

In an alternative disclosed embodiment, the composite concrete panel isconstructed as described above; however, the exterior architecturallayer 202 is formed from stucco, thin brick, tile, stone, stone veneer,such as limestone, granite, or marble, or metal panel facing and thelike. In such an embodiment, the stucco, thin brick, tile, stone, stoneveneer, such as limestone, granite, or marble, or metal panel facing andthe like is adhered to the layer of reinforcing material 16, if present,or to the exterior surface 60 of the foam insulating panel 14.

In an alternative disclosed embodiment, the composite concrete panel isconstructed as described above; however, the concrete panel 200 is madefrom a single layer of concrete, polymer modified concrete, polymermodified cement plaster, stucco, polymer modified geopolymer or polymermodified mortar and the exterior architectural layer 202 is formed fromtwo layers of polymer modified concrete, plaster or mortar in the mannerdisclosed in applicant's co-pending patent application Ser. No.13/626,087 filed Sep. 25, 2012. This method of forming a desired raisedpattern of brick, tile or stone on the exterior architectural layer 202is a relatively inexpensive and a relatively lightweight way to form acomposite concrete panel having a desired pattern or shape, such assimulated brick, limestone, granite, marble or the like thereon.

In an alternative disclosed embodiment, the composite insulated concretepanel is constructed as described above; however, no panel anchormembers, such as the panel anchor members 54, are used and no layer ofreinforcing material 16 is used. The concrete panel 200 is formeddirectly on the upper primary surface 75 of the foam insulating panel14, as described above. As a part of the present invention, it has beendiscovered that the concrete, plaster or mortar from which the concretepanel 200 is made forms a sufficiently strong adhesive bond with thefoam insulating panel 14 that it can support the weight of the foaminsulating panel and exterior architectural layer 202 without the panelanchor members, such as the panel anchor members 54, and without thelayer of reinforcing material 16. Furthermore, the exteriorarchitectural layer 202 also forms a sufficiently strong adhesive bondwith the foam insulating panel 14 that it can support its own weight.This is particularly true when the exterior architectural layer 202 ismade from a polymer modified concrete, polymer modified cement plaster,polymer modified geopolymer or polymer modified mortar, as describedabove, and the thickness of the exterior coating is not more than 2inches, preferably not more than 1 inch, most preferably approximately0.125 inches to approximately 0.5 inches. Additionally, it is preferredthat the concrete, plaster or mortar mix from which the exteriorarchitectural layer 202 is made include slag cement, or slag cement andfly ash, and reduced amounts of portland cement, or elimination ofportland cement, as described below. Also, it is preferred that theconcrete panel 200 be cured using the layer of insulating material 130(or heated concrete blanket or heated concrete form), as describedabove, or in a steam curing room. It is especially preferred that theconcrete panel 200 be cured in accordance with a predeterminedtemperature profile, as described above.

In an alternate disclosed embodiment, the exterior architectural layer202 is first poured onto a form casting surface. Then, the foaminsulating panel 14, with or without the layer of reinforcing material16, is placed on top of the exterior architectural layer 202, followedby the structural concrete layer 84, as described above. This way theentire composite panel can be cast at once with both structural andnon-structural wythes formed at the same time.

FIGS. 12-14 show an alternate disclosed embodiment of the presentinvention, which includes an opening, such as a window. Providing anopening in an exterior wall creates increased loads and/or stresses thatrequire additional reinforcement. FIG. 12 shows a composite reinforcedinsulated precast concrete panel 300 in accordance with the presentinvention that can be used in multistory construction. The compositereinforced insulated concrete panel 300 comprises a concrete panel 302,an attached foam insulating panel 304 and an exterior decorative layer306 and is made in the same manner as the composite reinforced insulatedconcrete panel 200 described above. However, in this embodiment anopening 308 is defined by the concrete panel 302 and the attached foaminsulating panel 304. Specifically, the foam insulating panel 304includes two transverse peripheral half channels 310, 312 and twolongitudinal peripheral half channels 314, 316 which extend the fullwidth and length of the foam insulating panel. The foam insulating panel304 also defines two intermediate transverse channels 318, 320 and twointermediate longitudinal channels 322, 324 which extend the full widthand length of the foam insulating panel. The transverse channels 318,320 and half channels 310, 312 define four concrete reinforcing columns326, 328, 330, 332, respectively. The longitudinal channels 322, 324 andhalf channels 314, 316 define four concrete reinforcing beams 334, 336,228, 340, respectively. As can be seen, the columns 326, 328 and thebeams 334, 336 frame the opening 308. The reinforcing columns 326-332extend the full width of the concrete panel 302. Similarly, thereinforcing beams 334-340 extend the full length of the concrete panel302. Since the reinforcing columns 326-332 and beams 334-340 extend thefull width and length of the concrete panel 302, they provide excellentrigidity to the concrete panel even though it includes the opening 308.Furthermore, since the reinforcing columns 326, 328 and beams 334, 336frame the opening 306, they provide a header, sill and joists into whicha window casement (not shown) can be attached.

By using the structural reinforcing elements, as described above,reduced amounts of concrete can be used in the concrete panel of thepresent invention compared to conventional concrete panels of the priorart. For example, for a 24 feet by 12 feet panel 200 of the design shownin FIGS. 1-4, 6-11, where the reinforcing columns are spaced 48 incheson center, the concrete reinforcing columns are 8 inches thick(thickness “E”) and 8 inches wide, while the concrete between thereinforcing columns is 3.5 to 4 inches thick (thickness “D”). Thisproduces a concrete panel 200 that requires approximately 40% by volumeless concrete than a concrete panel of 8 inches of uniform thickness ofsimilar properties. Similarly, for a 24 feet by 12 feet concrete panel302 of the design shown in FIGS. 12-14, where the reinforcing columnsare spaced 48 inches on center, the concrete reinforcing columns are 6inches thick (thickness “E”) and 6 inches wide, while the concretebetween the reinforcing columns are 3 inches thick (thickness “D”). Thisproduces a concrete panel 302 that requires approximately 40% by volumeless concrete than a concrete panel of 6 inches of uniform thickness ofsimilar properties. By reducing the amount of concrete required for thepanel, it reduces the amount of portland cement required, thereby alsoreducing the cost of the concrete panel. The reduced amount of concretealso reduces the weight of the concrete panel, which also reduces thestructural requirements to support the concrete panel, which alsoreduces cost. These savings are all realized without sacrificingstrength of the concrete panel, wind load or other load capability andflexural strength. In fact, the reinforced concrete panels of thepresent invention are more rigid, stronger, with higher structuralproperties than state of the art panels made with uniform thicknessconcrete.

FIGS. 15-19 show an alternate disclosed embodiment of the compositereinforced concrete panel of the present invention used as an exteriorwall of a building or other structure. Or, the same configuration can beused to construct a sound abatement panel, such as would be used along ahighway. FIGS. 15-19 show a first composite reinforced concrete panel400 and a second composite reinforced concrete panel 402 mountedvertically below the first composite reinforced concrete panel. Thefirst and second composite reinforced concrete panels 400, 402 areidentical to each other and are essentially identical to the compositereinforced concrete panel 212, except they are not use in loadbearingconditions. For example, the first composite reinforced concrete panel400 includes a reinforced concrete panel 404, an attached foaminsulating panel 406 and an exterior decorative layer 408 over a layerof reinforcing material 410. The concrete panel 404 includes a pluralityof reinforcing beams, such as the beams 412, 414, 415, 416, and aplurality of reinforcing columns, such as the columns 420, 422, 424. Thesecond composite reinforced concrete panel 402 includes a plurality ofreinforcing columns and beams, such as the beams 426, 428, 430.

Formed in each of the first and second composite reinforced concretepanel 400, 402 at the intersection of the peripheral columns, such asthe columns 420, 424, and the beams, such as the beams 412, 414, 415,416, 426, 428, 430 are a plurality of inserts, such as the inserts 432,434, 436, 438, 440, 442, 444, 446, 448, 450. Each insert 432-450, suchas the insert 436 (FIG. 19), includes a hollow sleeve 446 with femalethreads formed on the inside thereof, a plate 448 attached to the sleeveand an anchoring loop 450 attached to the plate. A rebar 452 passesthrough the anchoring loop 450 and hardened concrete within theanchoring loop securely attaches the inserts, such as the insert 436,securely in the concrete panel, such as the concrete panel 404.

The first and second composite reinforced concrete panels 400, 402 areeach attached to two vertically disposed concrete columns or preferablysteel I-beams 454, 456 horizontally spaced from each other a distanceequal to the length of the first composite reinforced concrete panel. Abolt, such as the bolt 460, passes through one of the flanges of theI-beams, such as the flange 462 of the I-beam 454, and is screwed intothe sleeve of each of the inserts, such as the sleeve 446 of the insert436 (FIG. 19).

The structure shown in FIG. 15 is constructed as follows. The twoI-beams 454, 456 and erected vertically and are secured in concretefootings (not shown) in the ground to hold the I-beams securely inposition. The I-beam 454 is horizontally spaced from the I-beam 456 adistance equal to the length of the first composite reinforced concretepanel 400. Holes are drilled in the flanges of each of the I-beams 454,456 and in alignment with the location of each of the inserts 432-450,such as a hole in the flange 462 of the I-beam 454 in alignment with theinsert 436. The second composite reinforced concrete panel 402 ispositioned vertically with its transverse edges against the flange ofeach of the I-beams 454, 456. The second composite reinforced concretepanel 402 is then attached to each of the I-beams 454, 456 by insertingbolts, such as the bolt 460, through the flange of each of the I-beamsinto the corresponding insert, such as the inserts 426-430, andtightening the bolts. Similarly, the first composite reinforced concretepanel 400 is positioned vertically with its transverse edges against theflange of each of the I-beams 454, 456 and above of the second compositereinforced concrete panel 402. The first composite reinforced concretepanel 400 is then attached to each of the I-beams 454, 456 by insertingbolts, such as the bolt 460, through the flange of each of the I-beamsinto the corresponding insert, such as the inserts 412-416, 444, andtightening the bolts.

The first and second composite reinforced concrete panels 400, 402 canbe attached to the I-beams 454, 456 with the exterior coating 408 on thelayer of reinforcing material 410, as shown in FIG. 15. Alternately, thefirst and second composite reinforced concrete panels 400, 402 can firstbe attached to the I-beams 454, 456 without the exterior coating 408.Then, the exterior coating 408 can be applied to both the first andsecond composite reinforced concrete panels 400, 402 at the same time.

Of course, additional composite reinforced concrete panels (not shown)can be positioned horizontally adjacent the first and second compositereinforced concrete panels 400, 402 and attached to the I-beams 454, 456to form a wall, sound barrier or other structure of a desired length orconfiguration. Furthermore, an additional composite reinforced concretepanel (not shown) can be positioned vertically adjacent; i.e., above,the first composite reinforced concrete panel 400, and attached to theI-beams 454, 456 to form a wall, sound barrier or other structure of anydesired height or configuration.

FIGS. 20 and 21 show an alternate disclosed embodiment of the compositereinforced concrete panels 400, 402. FIG. 20 discloses first and secondcomposite reinforced concrete panels 500, 502 identical to the first andsecond composite reinforced concrete panels 400, 402, except asdescribed below. The first and second composite reinforced concretepanels 500, 502 are used as roofing panels, and, therefore, are disposedhorizontally. The first and second composite reinforced concrete panels500, 502 are attached to a horizontal steel I-beam roof joist 504, whichis attached to and supported at opposite ends thereof by two verticalconcrete columns or preferably steel I-beams 506, 508. The first andsecond composite reinforced concrete panels 500, 502 are attached to thehorizontal I-beam roof joist 504 in the same manner as the first andsecond composite reinforced concrete panels 400, 402 are attached to theI-beams 454, 456; i.e., by inserting bolts, such as the bolt 460,through the flanges of the horizontal I-beam roof joist into a threadedinsert in the concrete panel, such as the inserts 432-450.

The first composite reinforced concrete panel 500 includes a reinforcedconcrete panel 510 attached to a foam insulating panel 512. The concretepanel 510 includes a plurality of reinforcing beams or ribs and aplurality of reinforcing columns or ribs identical to those shown forthe first and second composite reinforced concrete panels 400, 402. Thefirst and second composite reinforced concrete panels 500, 502 aredisposed with the concrete panel 510 facing the interior of a buildingor structure (i.e., facing down) and the foam insulating panel 512facing the exterior of the building or structure (i.e., facing up).

On the surface of the foam insulating panel 512 opposite the concretepanel 510 is a layer of base coat 514 for a fluid applied roof membrane,which is optionally used to attach or laminated to the layer ofreinforcing material 516. On top of the layer of reinforcing material516 is a second layer of fluid applied roof membrane 518. Seam tape 520is placed over the joint 522 between the first composite reinforcedconcrete panel 500 and the second composite reinforced concrete panel502. Then, a top coat of fluid applied roof membrane 524 is placed overthe seam tape 520 and the second layer of roof membrane 518 therebyforming the top layer of the roofing system.

Optionally, the first and second composite reinforced concrete panels500, 502 can include a layer of cementitious material (not shown),identical to the layer of cementitious material 408 of the firstcomposite reinforced concrete panel 400 disclosed above, on the layer ofreinforcing material 516. The fluid applied roof membrane systems canthen be applied on top of the layer of cementitious material of thefirst and second composite reinforced concrete panels 500, 502.

Fluid applied roof membranes are well known in the art. For example,Kemper System America, Inc., West Seneca, N.Y., USA sells a line offluid applied roof membrane products including Kempertec EP/EP5-Primerwith silica sand, Kempertec D-Primer, Kempertec AC primer with silicasand, Kempertec BSF-R Primer, Kemperol 2K-PUR with 165 fleece, KemperolBR/BR-M with 165 fleece, and Kempertec TC traffic surfacing. Theseproducts are polyurethane-based, polyester-based andpolymethylmethacrylate-based.

Sika Corporation, Lyndhurst, N.J., USA offers a fluid applied roofmembrane product under the designation Sikalastic® RoofPro LiquidApplied Membrane. This product includes Sika® Bonding Primer (a twocomponent prereacted epoxy resin dispersed in water and a waterbornemodified polyamine solution), Sikalastic® 601 BC and Sikalastic® 621 TCare both moisture cured polyurethane-based systems. Sika® Reemat andFlexitape systems are a nylon mesh reinforcing system.

Siplast USA, Irving, Tex., USA offers a fluid applied roof membraneproduct under the designation Parapro PMMA Roof Membrane System. Thisproduct includes primers designated Pro Primer R, Pro Primer W and ProPrimer T (all polymethylmethacrylate based resins); Paradiene 20underlayment and Parapro Roof Membrane Resin (a polymethylmethacrylatebased resin).

FIG. 21 discloses first and second composite reinforced concrete panels600, 602 identical to the first and second composite reinforced concretepanels 400, 402, except as described below. The first and secondcomposite reinforced concrete panels 600, 602 are used as roofingpanels, and, therefore, are disposed horizontally. The first and secondcomposite reinforced concrete panels 600, 602 are attached to ahorizontal steel I-beam roof joist 604, which is attached to andsupported at opposite ends thereof by two vertical steel I-beams 606,608. The first and second composite reinforced concrete panels 600, 602are attached to a horizontal I-beam roof joist 604 in the same manner asthe first and second composite reinforced concrete panels 400, 402 areattached to the I-beams 454, 456; i.e., by inserting bolts, such as thebolt 460, through the flanges of the horizontal I-beam roof joist into athreaded insert in the concrete panel, such as the inserts 432-450.

The first composite reinforced concrete panel 600 includes a reinforcedconcrete panel 610 attached to a foam insulating panel 612. The concretepanel 610 includes a plurality of reinforcing beams and a plurality ofreinforcing columns identical to those shown in the first and secondcomposite reinforced concrete panels 400, 402. The first and secondcomposite reinforced concrete panels 600, 602 are disposed with theconcrete panel 610 facing the interior of a building or structure (i.e.,facing down) and the foam insulating panel 612 facing the exterior ofthe building or structure (i.e., facing up).

On the surface of the foam insulating panel 612 opposite the concretepanel 610 is a liquid applied weather membrane 614, as described above,and a layer of reinforcing material 618. Optionally, on top of the layerof reinforcing material 618 is a layer of cementitious material 620. Thelayer of cementitious material 620 is identical to the layer ofcementitious material 408 of the first composite reinforced concretepanel 400 disclosed above. Seam tape 622 is placed over the joint 624between the first composite reinforced concrete panels 600 and thesecond composite reinforced concrete panels 602. On top of the seam tape622 and layer of cementitious material 620, if present, or the layer ofreinforcing material 618, if the layer of cementitious material is notpresent, are first and second sheets of polymeric roof membrane 626,628, such as EPDM (ethylene propylene diene monomer (M-call) rubber),PVC (polyvinyl chloride) or TPO (thermoplastic polyolefin). Thepolymeric roof membrane 626, 628 is attached to the layer ofcementitious material 620, if present, or the layer of reinforcingmaterial 618 by a suitable adhesive. The first sheet of polymeric roofmembrane 626 is attached to the second sheet of polymeric roof membrane628 by methods known in the art, such as by hot air welding.

Firestone Building Product, Indianapolis, Ind., USA offers a TPO roofmembrane system designated UltraPly TPO Roofing System and an EPDM roofmembrane system under the designation RubberGard EPDM. GAF Corp., Wayne,N.J., USA offers a TPO roof membrane system designated EverGardTPOsingle ply roofing membrane. Overlapping sheets of TPO roofing membrane,such as the sheets 626, 628, are joined together by hot air welding.

While the present invention can be used with conventional concretemixes; i.e., concrete in which portland cement is the only cementitiousmaterial used in the concrete, it is preferred as a part of the presentinvention to use the concrete, plaster or mortar mixes disclosed inapplicant's co-pending patent application Ser. No. 13/626,540 filed Sep.25, 2012 (the disclosure of which is incorporated herein by reference inits entirety). Concrete is a composite material consisting of amineral-based hydraulic binder which acts to adhere mineral particulatestogether in a solid mass; those particulates may consist of coarseaggregate (rock or gravel), fine aggregate (natural sand or crushedfines), and/or unhydrated or unreacted cement. Specifically, theconcrete mix in accordance with the present invention comprisescementitious material, aggregate and water sufficient to at leastpartially hydrate the cementitious material. The amount of cementitiousmaterial used relative to the total weight of the concrete variesdepending on the application and/or the strength of the concretedesired. Generally speaking, however, the cementitious materialcomprises approximately 25% to approximately 40% by weight of the totalweight of the concrete, exclusive of the water, or 300 lbs/yd³ ofconcrete (177 kg/m³) to 1,100 lbs/yd³ of concrete (650 kg/m³) ofconcrete. The water-to-cementitious material ratio by weight is usuallyapproximately 0.25 to approximately 0.7. Relatively lowwater-to-cementitious material ratios lead to higher strength but lowerworkability, while relatively high water-to-cementitious material ratioslead to lower strength, but better workability. Aggregate usuallycomprises 60% to 80% by volume of the concrete. However, the relativeamount of cementitious material to aggregate to water is not a criticalfeature of the present invention; conventional amounts can be used.Nevertheless, sufficient cementitious material should be used to produceconcrete with an ultimate compressive strength of at least 1,000 psi,preferably at least 2,000 psi, more preferably at least 3,000 psi, mostpreferably at least 4,000 psi, especially up to about 10,000 psi ormore.

The aggregate used in the concrete used with the present invention isnot critical and can be any aggregate typically used in concreteincluding, but not limited to, aggregate meeting the requirements ofASTM C33. The aggregate that is used in the concrete depends on theapplication and/or the strength of the concrete desired. Such aggregateincludes, but is not limited to, fine aggregate, medium aggregate,coarse aggregate, sand, gravel, crushed stone, lightweight aggregate,recycled aggregate, such as from construction, demolition and excavationwaste, and mixtures and combinations thereof.

The preferred cementitious material for use with the present inventioncomprises portland cement; preferably portland cement and one of slagcement or fly ash; and more preferably portland cement, slag cement andfly ash. Slag cement is also known as ground granulated blast-furnaceslag (GGBFS). The cementitious material preferably comprises a reducedamount of portland cement and increased amounts of recycledsupplementary cementitious materials; i.e., slag cement and/or fly ash.This results in cementitious material and concrete that is moreenvironmentally friendly. One or more cementitious materials other thanslag cement or fly ash can also replace the portland cement, in whole orin part. Such other cementitious or pozzolanic materials include, butare not limited to, silica fume; metakaolin; rice hull (or rice husk)ash; ground burnt clay bricks; brick dust; bone ash; animal blood; clay;other siliceous, aluminous or aluminosiliceous materials that react withcalcium hydroxide in the presence of water; hydroxide-containingcompounds, such as sodium hydroxide, magnesium hydroxide, or any othercompound having reactive hydrogen groups, other hydraulic cements andother pozzolanic materials. The portland cement can also be replaced, inwhole or in part, by one or more inert or filler materials other thanportland cement, slag cement or fly ash. Such other inert or fillermaterials include, but are not limited to, limestone powder; calciumcarbonate; titanium dioxide; quartz; or other finely divided mineralsthat densify the hydrated cement paste.

The preferred cementitious material for use with a disclosed embodimentof the present invention comprises 0% to approximately 100% by weightportland cement; preferably, 0% to approximately 80% by weight portlandcement. The ranges of 0% to approximately 100% by weight portland cementand 0% to approximately 80% by weight portland cement include all of theintermediate percentages; such as, 5%, 10%, 15%, 20%, 25%, 30%, 35%,40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% and 95%. Thecementitious material of the present invention can also comprise 0% toapproximately 90% by weight portland cement, preferably 0% toapproximately 80% by weight portland cement, preferably 0% toapproximately 70% by weight portland cement, more preferably 0% toapproximately 60% by weight portland cement, most preferably 0% toapproximately 50% by weight portland cement, especially 0% toapproximately 40% by weight portland cement, more especially 0% toapproximately 30% by weight portland cement, most especially 0% toapproximately 20% by weight portland cement, or 0% to approximately 10%by weight portland cement. In one disclosed embodiment, the cementitiousmaterial comprises approximately 10% to approximately 45% by weightportland cement, more preferably approximately 10% to approximately 40%by weight portland cement, most preferably approximately 10% toapproximately 35% by weight portland cement, especially approximately33⅓% by weight portland cement, most especially approximately 10% toapproximately 30% by weight portland cement. In another disclosedembodiment of the present invention, the cementitious material comprisesapproximately 5% by weight portland cement, approximately 10% by weightportland cement, approximately 15% by weight portland cement,approximately 20% by weight portland cement, approximately 25% by weightportland cement, approximately 30% by weight portland cement,approximately 35% by weight portland cement, approximately 40% by weightportland cement, approximately 45% by weight portland cement orapproximately 50% by weight portland cement or any sub-combinationthereof.

The preferred cementitious material for use in one disclosed embodimentof the present invention also comprises 0% to approximately 90% byweight slag cement, preferably approximately 20% to approximately 90% byweight slag cement, more preferably approximately 30% to approximately80% by weight slag cement, most preferably approximately 30% toapproximately 70% by weight slag cement, especially approximately 30% toapproximately 60% by weight slag cement, more especially approximately30% to approximately 50% by weight slag cement, most especiallyapproximately 30% to approximately 40% by weight slag cement. In anotherdisclosed embodiment the cementitious material comprises approximately33⅓% by weight slag cement. In another disclosed embodiment of thepresent invention, the cementitious material can comprise approximately5% by weight slag cement, approximately 10% by weight slag cement,approximately 15% by weight slag cement, approximately 20% by weightslag cement, approximately 25% by weight slag cement, approximately 30%by weight slag cement, approximately 35% by weight slag cement,approximately 40% by weight slag cement, approximately 45% by weightslag cement, approximately 50% by weight slag cement, approximately 55%by weight slag cement, approximately 60% by weight slag cement,approximately 65%, approximately 70% by weight slag cement,approximately 75% by weight slag cement, approximately 80% by weightslag cement, approximately 85% by weight slag cement or approximately90% by weight slag cement or any sub-combination thereof.

The preferred cementitious material for use in one disclosed embodimentof the present invention, especially for the concrete panel 200, alsocomprises 0% to approximately 50% by weight fly ash; preferablyapproximately 10% to approximately 45% by weight fly ash, morepreferably approximately 10% to approximately 40% by weight fly ash,most preferably approximately 10% to approximately 35% by weight flyash, especially approximately 33⅓% by weight fly ash. In anotherdisclosed embodiment of the present invention, the preferredcementitious material comprises 0% by weight fly ash, approximately 5%by weight fly ash, approximately 10% by weight fly ash, approximately15% by weight fly ash, approximately 20% by weight fly ash,approximately 25% by weight fly ash, approximately 30% by weight flyash, approximately 35% by weight fly ash, approximately 40% by weightfly ash, approximately 45% by weight fly ash or approximately 50% byweight fly ash or any sub-combination thereof. Preferably the fly ashhas an average particle size of <10 μm; more preferably 90% or more ofthe particles have a particles size of <10 μm.

The preferred cementitious material for use in one disclosed embodimentof the present invention, especially for the exterior architecturallayer 202, also comprises 0% to approximately 80% by weight fly ash,preferably approximately 10% to approximately 75% by weight fly ash,preferably approximately 10% to approximately 70% by weight fly ash,preferably approximately 10% to approximately 65% by weight fly ash,preferably approximately 10% to approximately 60% by weight fly ash,preferably approximately 10% to approximately 55% by weight fly ash,preferably approximately 10% to approximately 50% by weight fly ash,preferably approximately 10% to approximately 45% by weight fly ash,more preferably approximately 10% to approximately 40% by weight flyash, most preferably approximately 10% to approximately 35% by weightfly ash, especially approximately 33⅓% by weight fly ash. In anotherdisclosed embodiment of the present invention, the preferredcementitious material comprises 0% by weight fly ash, approximately 5%by weight fly ash, approximately 10% by weight fly ash, approximately15% by weight fly ash, approximately 20% by weight fly ash,approximately 25% by weight fly ash, approximately 30% by weight flyash, approximately 35% by weight fly ash, approximately 40% by weightfly ash, approximately 45% by weight fly ash or approximately 50% byweight fly ash, approximately 55% by weight fly ash, approximately 60%by weight fly ash, approximately 65% by weight fly ash, approximately70% by weight fly ash or approximately 75% by weight fly ash,approximately 80% by weight fly ash or any sub-combination thereof.Preferably the fly ash has an average particle size of <10 μm; morepreferably 90% or more of the particles have a particles size of <10 μm.

In one disclosed embodiment, the preferred cementitious material for usewith the present invention comprises approximately equal parts by weightof portland cement, slag cement and fly ash; i.e., approximately 33⅓% byweight portland cement, approximately 33⅓% by weight slag cement andapproximately 33⅓% by weight fly ash. In another disclosed embodiment, apreferred cementitious material for use with the present invention has aweight ratio of portland cement to slag cement to fly ash of 1:1:1. Inanother disclosed embodiment, the preferred cementitious material foruse with the present invention has a weight ratio of portland cement toslag cement to fly ash of approximately 0.85-1.15:0.85-1.15:0.85-1.15,preferably approximately 0.9-1.1:0.9-1.1:0.9-1.1, more preferablyapproximately 0.95-1.05:0.95-1.05:0.95-1.05.

The cementitious material disclosed above can also optionally include 0%to approximately 50% by weight ceramic fibers, preferably 0% to 40% byweight ceramic fibers, more preferably 0% to 30% by weight ceramicfibers, most preferably 0% to 20% by weight ceramic fibers, especially0% to 15% by weight ceramic fibers, more especially 0% to 10% by weightceramic fibers, most especially 0% to 5% by weight ceramic fibers.Wollastonite is an example of a ceramic fiber. Wollastonite is a calciuminosilicate mineral (CaSiO₃) that may contain small amounts of iron,magnesium, and manganese substituted for calcium. In addition thecementitious material can optionally include 0.1-25% calcium oxide(quick lime), calcium hydroxide (hydrated lime), calcium carbonate orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups.

In one disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 100% by weight portlandcement, 0% to approximately 90% by weight slag cement, and 0% toapproximately 80% by weight fly ash. In one disclosed embodiment, thecementitious material for use with the present invention comprises 0% toapproximately 80% by weight portland cement, 0% to approximately 90% byweight slag cement, and 0% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 70% by weight portlandcement, 0% to approximately 90% by weight slag cement, and 0% toapproximately 80% by weight fly ash. In another disclosed embodiment,the cementitious material for use with the present invention comprises0% to approximately 60% by weight portland cement, 0% to approximately90% by weight slag cement, and 0% to approximately 80% by weight flyash. In another disclosed embodiment, the cementitious material for usewith the present invention comprises 0% to approximately 50% by weightportland cement, 0% to approximately 90% by weight slag cement, and 0%to approximately 80% by weight fly ash. In another disclosed embodiment,the cementitious material for use with the present invention comprisesless than 50% by weight portland cement, 10% to approximately 90% byweight slag cement, and 10% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 45% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and 10% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 40% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, and 10% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 35% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, and 10% to approximately 80% by weight fly ash.

In another disclosed embodiment, the cementitious material for use withthe present invention, especially for the exterior architectural layer202, comprises 0% to approximately 100% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to 10% by weight Wollastonite; and 0% toapproximately 25% by weight calcium oxide, calcium hydroxide, latex,acrylic or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 80% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 10% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 70% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 10% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 60% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 10% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 50% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 10% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises less than 50% by weight portland cement; 10% to approximately90% by weight slag cement; 10% to approximately 80% by weight fly ash;0% to approximately 10% by weight Wollastonite; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; 0% to approximately 10% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 10% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 35% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; 0% to approximately 10% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to 15% by weight ceramicfiber. In one disclosed embodiment, the cementitious material for usewith the present invention comprises 0% to approximately 80% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to approximately 15% byweight ceramic fiber. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises 0% toapproximately 70% by weight portland cement; 0% to approximately 90% byweight slag cement; 0% to approximately 80% by weight fly ash; and 0.1%to approximately 10% by weight ceramic fiber. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 60% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; and 0.1% to approximately 10% by weight ceramic fiber.In another disclosed embodiment, the cementitious material for use withthe present invention comprises 0% to approximately 50% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to approximately 10% byweight ceramic fiber. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises less than 50% byweight portland cement; 10% to approximately 90% by weight slag cement;10% to approximately 80% by weight fly ash; and 0.1% to approximately10% by weight ceramic fiber. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; and 0.1% to approximately 10% byweight ceramic fiber. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 40% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; and 0.1% to approximately 10% by weight ceramic fiber.In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 35%by weight portland cement; approximately 10% to approximately 90% byweight slag cement; 10% to approximately 80% by weight fly ash; and 0.1%to approximately 10% by weight ceramic fiber.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; 0% to 30% by weight Wollastonite;and 0% to approximately 25% by weight calcium oxide, calcium hydroxide,or latex, acrylic, or polymer admixtures, either mineral or synthetic,that have reactive hydroxyl groups, or mixtures thereof. In onedisclosed embodiment, the cementitious material for use with the presentinvention comprises 0% to approximately 80% by weight portland cement;0% to approximately 90% by weight slag cement; 0% to approximately 80%by weight fly ash; 0% to approximately 30% by weight Wollastonite; and0% to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 70% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 60% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 50% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises less than 50% by weight portland cement; 10% to approximately90% by weight slag cement; 10% to approximately 80% by weight fly ash;0% to approximately 30% by weight Wollastonite; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; 0% to approximately 30% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 10% to approximately 80% by weight fly ash; 0% toapproximately 30% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 35% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to 30% by weightWollastonite. In one disclosed embodiment, the cementitious material foruse with the present invention comprises 0% to approximately 80% byweight portland cement; 0% to approximately 90% by weight slag cement;0% to approximately 80% by weight fly ash; and 0.1% to approximately 30%by weight Wollastonite. In another disclosed embodiment, thecementitious material for use with the present invention comprises 0% toapproximately 70% by weight portland cement; 0% to approximately 90% byweight slag cement; 0% to approximately 80% by weight fly ash; and 0.1%to approximately 30% by weight Wollastonite. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 60% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; and 0.1% to approximately 30% by weight Wollastonite. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 50% by weight portlandcement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to approximately 30% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises less than 50% byweight portland cement; 10% to approximately 90% by weight slag cement;10% to approximately 80% by weight fly ash; and 0.1% to approximately30% by weight Wollastonite. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; and 0.1% to approximately 30% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 40% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; and 0.1% to approximately 30% by weight Wollastonite. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 35% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 10% to approximately 80% by weight fly ash; and 0.1% toapproximately 30% by weight Wollastonite.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash, wherein the combination of portlandcement, slag cement and fly ash comprise at least 50% by weight; and0.1% to approximately 50% by weight polymer for making polymer modifiedconcrete, mortar or plaster. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; and 0.1% to approximately 50% byweight polymer for making polymer modified concrete, mortar or plaster.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash, wherein the combination of portlandcement, slag cement and fly ash comprise at least 50% by weight; and0.1% to approximately 50% by weight ceramic fiber. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 45% by weight portlandcement; approximately 10% to approximately 90% by weight slag cement;10% to approximately 80% by weight fly ash; and 0.1% to approximately50% by weight ceramic fiber.

In another disclosed embodiment, the cementitious material for use withthe present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash, wherein the combination of portlandcement, slag cement and fly ash comprise at least 50% by weight; 0.1% toapproximately 50% by weight ceramic fiber and 0.1% to approximately 50%by weight polymer for making polymer modified concrete, mortar orplaster. In another disclosed embodiment, the cementitious material foruse with the present invention comprises approximately 10% toapproximately 45% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; and 0.1% to approximately 50% by weight ceramic fiberand 0.1% to approximately 50% by weight polymer for making polymermodified concrete, mortar or plaster.

The portland cement, slag cement and fly ash can be combined physicallyor mechanically in any suitable manner and is not a critical feature.For example, the portland cement, slag cement and fly ash can be mixedtogether to form a uniform blend of dry material prior to combining withthe aggregate and water. If dry polymer powder is used, it can becombined with the cementitious material and mixed together to form auniform blend prior to combining with the aggregate or water. If thepolymer is a liquid, it can be added to the cementitious material andcombined with the aggregate and water. Or, the portland cement, slagcement and fly ash can be added separately to a conventional concretemixer, such as the transit mixer of a ready-mix concrete truck, at abatch plant. The water and aggregate can be added to the mixer beforethe cementitious material, however, it is preferable to add thecementitious material first, the water second, the aggregate third andany makeup water last.

Chemical admixtures can also be used with the preferred concrete for usewith the present invention. Such chemical admixtures include, but arenot limited to, accelerators, retarders, air entrainments, plasticizers,superplasticizers, coloring pigments, corrosion inhibitors, bondingagents and pumping aid. Although chemical admixtures can be used withthe concrete of the present invention, it is believed that chemicaladmixtures are not necessary.

Mineral admixtures or additional supplementary cementitious material(“SCM”) can also be used with the concrete of the present invention.Such mineral admixtures include, but are not limited to, silica fume andhigh reactivity metakaolin. Although mineral admixtures can be used withthe concrete of the present invention, it is believed that mineraladmixtures are not necessary.

For the thin exterior architectural layer 202, any type of mortar,stucco, geopolymers, cement plaster, cementitious or polymer modifiedcement, polymer modified plaster, polymer modified mortar, stucco,acrylic base coat and finish coat materials can be used to achieve anyarchitectural type finish, texture or color.

The concrete mix cured in a concrete form in which the temperature ofthe curing concrete is controlled in accordance with the presentinvention, especially controlled to follow a predetermined temperatureprofile, produces concrete with superior early strength and ultimatestrength properties compared to the same concrete mix cured in aconventional form without the use of any chemical additives toaccelerate or otherwise alter the curing process. Thus, in one disclosedembodiment of the present invention, the preferred cementitious materialcomprises at least two of portland cement, slag cement and fly ash inamounts such that at seven days the concrete mix cured in accordancewith the present invention has a compressive strength at least 25%greater than the same concrete mix would have after seven days in aconventional (i.e., non-insulated) concrete form under ambientconditions. In another disclosed embodiment, the preferred concrete mixcured in accordance with the present invention has a compressivestrength at least 50%, at least 100%, at least 150%, at least 200%, atleast 250% or at least 300% greater than the same concrete mix wouldhave after seven days in a conventional (i.e., non-insulated) concreteform under the same conditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement, slag cement and fly ashin amounts such that at seven days the concrete mix cured in accordancewith the present invention has a compressive strength at least 25%greater than the same concrete mix would have after seven days in aconventional concrete form under ambient conditions. In anotherdisclosed embodiment the preferred concrete mix cured in accordance withthe present invention has a compressive strength at least 50%, at least100%, at least 150%, at least 200%, at least 250% or at least 300%greater than the same concrete mix would have after seven days in aconventional (i.e., non-insulated) concrete form under the sameconditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement and slag cement inamounts such that at seven days the concrete mix cured in accordancewith the present invention has a compressive strength at least 25%greater than the same concrete mix would have after seven days in aconventional concrete form under ambient conditions. In anotherdisclosed embodiment, the preferred concrete mix cured in accordancewith the present invention has a compressive strength at least 50%, atleast 100%, at least 150%, at least 200%, at least 250% or at least 300%greater than the same concrete mix would have after seven days in aconventional (i.e., non-insulated) concrete form under the sameconditions.

In another disclosed embodiment of the present invention, the preferredcementitious material comprises portland cement and fly ash in amountssuch that at seven days the concrete mix cured in accordance with thepresent invention has a compressive strength at least 25% greater thanthe same concrete mix would have after seven days in a conventionalconcrete form under ambient conditions. In another disclosed embodimentthe preferred concrete mix cured in accordance with the presentinvention has a compressive strength at least 50%, at least 100%, atleast 150%, at least 200%, at least 250% or at least 300% greater thanthe same concrete mix would have after seven days in a conventional(i.e., non-insulated) concrete form under the same conditions.

As a part of the present invention, it has been found that concrete,mortar or other cementitious-based materials, especially polymermodified concrete, will bond quite securely with expanded polystyrenefoam that has been cut from a block of foam that was first formed in amold. During expanded polystyrene manufacture, the foam beads are fusedwith steam under high pressure. Under steam and pressure, the foam beadsexpand against the surface of the mold encasement. During this process,the exterior surface of the expanded polystyrene block is more compactand dense. The exterior surface of the molded block is made of each ofthe unmolested foam beads pressed against the molding surface. Once thefoam block is cured and cut with a hot wire, the fresh cut surface has amore complex interstitial space opened up between the individually cutfoam beads. Polystyrene beads start softening at a temperature ofapproximately 80 to 90° C. Neopor brand expanded polystyrene board hasan even lower melting point then standard expanded polystyrene board. Inthe present concrete form when the concrete heat of hydration isretained by insulation, the concrete can reach up to 60-70° C. for asustained period of time. The expanded polystyrene board kept in directcontact with the concrete at elevated temperatures for an extendedperiod of time close to the polystyrene softening temperature will fuseor bond to the concrete better than the foam will bond to the sameconcrete at normal ambient temperature. In addition the openedindividual cell structure created by the cutting wire or knives providesan even better bond with concrete at elevated temperature. This is asignificant improvement of adhesion between concrete and any extruded orexpanded foam panels that have not been cut into sheets from an initialblock so that the surface of the foam does not have a polished or shinnysurface. Suitable polystyrene foam can be obtained by cutting, such aswith a knife blade, a saw or a hot wire, foam panels of a desiredthickness from a larger block of polystyrene foam. The polystyrene ispreferably polystyrene that includes graphite particles within thepolystyrene beads such as made by BASF under the trademark Neopor® andwhich is commercially available from Georgia Foam, Gainesville, Ga. andsuch as disclosed in U.S. Pat. Nos. 6,130,265; 6,362,242; 6,340,713; and6,414,041 (the disclosures of which are all incorporated herein byreference in their entirety). The bond between the concrete, mortar orother cementitious-based materials and polystyrene foam is also enhancedby using the concrete mix comprising portland cement, slag cement andfly ash, as disclosed above. Furthermore, the bond between the concrete,mortar or other cementitious-based materials and polystyrene foam isalso enhanced by curing the concrete, mortar or other cementitious-basedmaterials in insulated concrete forms or molds, as disclosed herein.Additionally, the bond between the concrete, mortar or othercementitious-based materials and polystyrene foam is also enhanced bycuring the concrete, mortar or other cementitious-based materials atelevated temperatures, such as produced by the hydration of cementitiousmaterial and retained by the insulated concrete forms, electricallyheated blankets, electrically heated concrete forms or steam curing, forexample above 120° F. (approximately 50° C.), preferably above 140° F.(approximately 60° C.), for an extended period of time, such as 12 hoursto 1 day; preferably, 1 day to 3 days, most preferably above 150° F.(approximately 65° C.) for 1 to 12 hours. Under these conditions, theconcrete, mortar or other cementitious-based materials and polystyrenefoam seem to fuse together. In fact, the bond between the concrete,mortar or other cementitious-based materials and polystyrene foam, asdisclosed above, is so strong that the bond between individualpolystyrene foam beads will fail before the bond between the concrete,mortar or other cementitious-based materials and the polystyrene foam.

It is specifically contemplated that the cementitious-based materialfrom which the concrete panel 200 and the exterior architectural layer202 are made can include reinforcing fibers made from materialincluding, but not limited to, steel, plastic polymers, glass, basalt,carbon, and the like. Many different types of steel fibers are known andcan be used in the present invention, such as those disclosed in U.S.Pat. Nos. 6,235,108; 7,419,543 and 7,641,731 and PCT patent applicationInternational Publication Nos. WO 2012/080326 and WO 2012/080323 (thedisclosures of which are incorporated herein by reference in theirentireties). Particularly preferred steel fibers are Dramix® 3D, 4D and5D steel fibers available from Bekaert, Belgium and Bekaert Corp.,Marietta, Ga., USA. Plastic fibers can also be used, such as thosedisclosed in U.S. Pat. Nos. 6,753,081; 6,569,525 and 5,628,822 (thedisclosures of which are incorporated herein by reference in theirentireties). It is also preferred to use ceramic fibers, especiallyacicular type fibers, such as Wollastonite, in the concrete used for theconcrete panel 200 and the exterior architectural layer 202. The use ofreinforcing fibers is particularly preferred in the concrete panel 200and the exterior architectural layer 202 made from polymer modifiedconcrete, polymer modified mortar and polymer modified plasters, whichprovide the lightweight composite insulated concrete panel in accordancewith the present invention improved flexural strength, as well asimproved wind load capability and blast resistance.

Although the concrete panels 200, 302 are shown as being used asvertical wall components, it is specifically contemplated that theconcrete panels can be used for horizontal applications, such aselevated slabs, such as parking lot decks or multistory buildingflooring. For such horizontal applications, it may be desirable toinclude additional reinforcing depending on design criteria. In suchcases, pre-tension or post-tension cables can be included in theconcrete panels 200, 302, specifically by placing the cables in thereinforcing elements, such as columns, beams and ribs, such as withinone or more of the beams 88, 100, 104 and columns 86, 90-98, 102.Suitable post-tension cables are commercially available from ContinentalStructures, Alpharetta, Ga., USA.

It should be understood, of course, that the foregoing relates only tocertain disclosed embodiments of the present invention and that numerousmodifications or alterations may be made therein without departing fromthe spirit and scope of the invention as set forth in the appendedclaims.

1-20. (canceled)
 21. A method comprising: placing a quantity of plastic concrete on a first primary surface of a foam insulating panel, wherein the foam insulating panel has a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, wherein the at least one recessed channel is sized and shaped to provide a mold for a concrete structural reinforcing member, and wherein the second primary surface defines a continuous plane; and filling the at least one recessed channel with the plastic concrete so as to provide a concrete structural reinforcing member for the concrete panel, wherein the plastic concrete has a first primary surface and an opposite second primary surface such that an elongate anchor member in the foam insulating panel extends from the first primary surface of the foam insulating panel into the plastic concrete, wherein the elongate anchor member has a definite length defined by a first end and an opposite second end, wherein the first end comprises a first enlarged portion flush with the second primary surface of the foam insulating panel and wherein the second end of the elongate anchor member is disposed between the first and second primary surfaces of the plastic concrete and wherein the second end comprises a second enlarged portion such that the second end interlocks with the plastic concrete.
 22. The method of claim 21, wherein the foam insulating panel comprises expanded polystyrene foam, polyisocyanurate foam or polyurethane foam.
 23. The method of claim 21, wherein the elongate anchor member extends through the foam insulating panel from the second primary surface to the first primary surface.
 24. The method of claim 21, wherein the foam insulating panel defines a plurality of recessed channels in the first primary surface, the recessed channels being sized and shaped to provide a mold for a concrete structural reinforcing member and wherein the concrete panel fills the plurality of recessed channels providing a plurality of concrete structural reinforcing members for the concrete panel.
 25. The method of claim 24, wherein the plurality of channel are formed at least around the periphery of the foam insulating panel.
 26. The method of claim 25, wherein the plurality of channels include at least one intermediate horizontal channel extending the full width of the foam insulating panel.
 27. The method of claim 21 further comprising a layer of reinforcing material disposed on the second primary surface of the foam insulating panel.
 28. The method of claim 21 further comprising a layer of cementitious material on the second primary surface of the foam insulating panel.
 29. The method of claim 27 further comprising a layer of cementitious material on the layer of reinforcing material.
 30. The method of claim 29, wherein the cementitious material is a polymer modified cementitious material.
 31. The method of claim 21, wherein the plurality of recessed channels are parallel to and spaced from each other.
 32. A method comprising: providing a layer of foam insulating material, wherein the layer of foam insulating material has a first primary surface and an opposite second primary and a layer of reinforcing material disposed on, substantially covering and adhered to the second primary surface of the layer of foam insulating material, wherein the second primary surface defines a continuous plane; inserting a plurality of elongate anchor members through the layer of reinforcing material and into a plurality of holes defined by the layer of foam insulating material, each elongate anchor member having a definite length defined by a first end and an opposite second end, a first portion of the anchor member extending from the first primary surface to the second primary surface of the layer of foam insulating material, a second portion of the anchor member extending outwardly from the first primary surface of the layer of foam insulating material and wherein the first enlarged portion is flush with the layer of reinforcing material; placing a quantity of plastic concrete on the first primary surface of the layer of foam insulating material such that the second end of the elongate anchor member is disposed within the quantity of plastic concrete.
 33. The method of claim 32 wherein the second end of the elongate anchor member comprises a second enlarged portion.
 34. The method of claim 32 further comprising forming a layer of cementitious material on the layer of reinforcing material.
 35. The method of claim 34, wherein the cementitious material is a polymer modified cementitious material.
 36. The method of claim 32, wherein at least a portion of the layer of reinforcing material is captured between the first enlarged portion of each of the plurality of elongate anchor members and the second primary surface of the layer of foam insulating material.
 37. The method of claim 32, wherein the layer of reinforcing material is a continuous material or a discontinuous material.
 38. The method of claim 32, wherein the layer of reinforcing material a fabric, a mesh or a web.
 39. The method of claim 38, wherein the fabric, mesh or web is made from polymer fibers, fiberglass, basalt fibers, aramid fibers, or carbon fibers.
 40. The method of claim 32, wherein the layer of reinforcing material is a fiberglass mesh. 